SERVICE MANUAL - Valeo Compressors
Contents
1. Y jer nb Oil passage Radial bearing Reservoir Thrust bearing Oil passage 1 Product description Compressor 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 Operation conditions table 3 The compressor must be operated under the temperature Speed Maximum 7 000 rpm P Continuous 6 000 rpm Maximum 2 4 MPaG 24 5kgf cm 348 psig 10 4 conditions shown in the operation conditions table shown at the left CAUTION The A C cycle components must be designed so that the pressure in the cycle does not exceed 2 4 MPaG 20 kgf cm 348 psig Inclination limit at installation The compressor must be installed on the vehicle within the inclination range shown at the left Compressor bracket 1 Install the bracket securely on the chassis frame or engine body As the engine vibrations may be sev2. Flexible hose Low pressure connector 569501 0520 Running in operation 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 2 Install the compressor on the test bench 3 Install the high pressure connector 569501 0420 and the low pressure connector 569501 0520 to the ports and tighten the bolts to the specified torque Specified torque 20 24 Nem 2 0 2 4 kgf m 14 17 Ibf ft 4 Connect the two connector ports using a flexible hose 5 Run the compressor at 1 000 rpm for at least 30 minutes 6 Replace 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 system 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 19 3 Handling instructions Valve asse
3. Thrust bearing Piston drive system The pistons in the cylinders are mounted on the swash plate through a drive ball and a shoe disk Each piston has a compression head at each end The rotation of the 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 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 aR
4. SERVICE MANUAL Valeo TM3 1 Compressor added II Copyright 2014 Valeo Japan CO LTD All rights reserved Foreword This service manual has been elaborated to help service personnel to provide efficient and correct service and maintenance on the TM31 formerly called DKS 32 compressor for HFC 134a for auto motive air conditioning This manual includes the operation specifications procedures for disassembly reassembly and inspection of the compressor 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 WARNINGS 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 Maintenance must be properly done to avoid serious injury risks Improper maintenance can result in injury or property damage MEANING OF MARKS 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 ontents 1 P
5. 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 22 23 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 24 25 Compressor troubleshooting tree 1 Insufficient cooling capacity A Compressor is not running B Compressor is running C Compressor runs intermittently 2 Abnormal noise A Abnormal noise from compressor B Abnormal noise from magnetic clutch C Belt slipping noise 3 Smoke A Magnetic clutch friction surface slipping B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor l NJ l 4 Troubleshooting Compressor is not running No cool blow coming out Compressor is running No cool blow coming out Insufficient cooling capacity Symptom IMagnetic clutch slips when turning on the A C switch Low pressure cut switch operate see p 24 25 The magnetic clutch slips or does not engage when the compressor runs The magnetic clutch engages but the armature does not
6. Current Compressor Is Compressor replaced is kept Amount to remove from new compressor Same as recovered unit cu IN Specified Amount charge recovered Charging amount 30 5 amount recovered 1 2 Same as recovered 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 Therefore refer to the table at 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 14 16 Nem 1 4 1 6 kgf m 10 3 11 8 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 100 cm 6 1 cu in 60 cm 3 7 cu in 30 cm 1 8 cu in 30 cm 1 8 cu in After installing these component parts check the compressor oil See p 16 18 3 Handling instructions High pressure connector JED 569501 0420 O rin g 569300 9200 3s
7. 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 24 25 The magnetic clutch slips or does not engage when the compressor is running Belt slipping 7 The magnetic clutch does Inot engage Both discharge and suction pressures are high The magnetic clutch slips or does not engage when the compressor is running The magnetic clutch does pot engage Possible cause Compressor internal part damage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly Magnetic clutch damage Magnetic clutch air gap too wide Low magnetic clutch voltage H Belt slipping Compressor internal part damage or magnetic clutch damage Bolt drop off Armature drop off l No difference of temperature Refrigerant shortage Magnetic clutch friction surface slipping Loose connection of the Limagnetic clutch electrical circuit Magnetic clutch belt slipping H Defective sensor Excess of refrigerant Condenser fan failure Loose connection of the magnetic clutch electrical circuit Defective sensor efect 22 Measure Replace the compressor Fix the refrigerant leakage then fill with refrigerant until reaching the right amount Replace the lead wire if it is defective Repair or replace the mag
8. 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 Refrigerant handling WARNING 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 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 14 3 Handling instructions Do not release refrigerant into the air GI 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 syste
9. substances e Metal filings 7 i Charge specified quantity GS of compressor oil Oil filler plug GE Oil contamination Unlike engine oil no cleaning agent is added 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 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 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 p 16 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 Fillthe compressor with the specified amount of oil through the oil filler plug see p 18 1 3 Handling instructions Current Compressor IS Compressor replaced is kept Amount to remove from new compressor unit cm amp cc Specified Amount charge recovered Charging amount 500 amount recovered 20
10. 39 or 37 0 32 2 Dual pressure switch A dual pressure switch is necessary The following specifications are recommended 0 19 1 9 27 1 47 115 213 Compressor OFF High pressure control 2 65 MPaG 27 kgf cm 384 psig or AT 11 8 26 2 65 127 384 higher Low pressure control 0 18 MPaG 1 8 kgf cm 26 psig or lower ON The dual pressure switch controls high and low pressure High pressure control When abnormally high pressure develops the compressor is turned OFF to protect the system Low pressure control When there is insufficient refrigerant in the system compressor operation is stopped to prevent the compressor from seizing 12 2 Operation precautions 13 During the off season of the air conditioner operate the compressor for a few minutes once a week Do not drive through water Water may damage the magnetic clutch thus preventing normal operation Do not allow a compressor that has not been used for a long period to become wet Always charge the A C system with the specified quantity of refrigerant Keep the compressor clear of water projection while cleaning the vehicule 3 Handling instructions 1 Maintenance precautions Work area As the components of air conditioners are particularly sensitive to moisture dirt and
11. CAUTION Align the roll pins and tap the head lightly and evenly with a plastic hammer pe Remove the guide 597067 6100 9 Install the five bolts from the front cylinder head side and tighten them to the specified torque Specified torque 25 29 Nem 2 5 3 0 kgf m 18 22 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 14 16 Nem 1 4 1 6 kgf m 10 12 Ibf ft 13 Install the strainer in the suction port When the connectors are installed 14 Fit blanking plates to the suction and discharge connections and tighten it to the specified torque Specified torque 20 24 Nem 2 0 2 4 kgf m 14 17 Ibf ft 15 Install the magnetic clutch see p 29 16 Run in the compressor see p 19 17 Perform the leak test see p 20 38 9 Service tools In addition to standard tools numerous special tools are necessary to service the Valeo TM3 I 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
12. L DH PS 500 cc 30 5 cu in 9 5 kg 21 Ib w o Clutch w o oil DIMENSIONS with clutch 278 5 143 178 mm Length Width Height 10 94 5 63 7 in MOUNTING Direct side or base Valeo TM31 Application limits for HFC 134a MPaA MPaG Saturated condensing conditions tc Condensing temperature te Evaporating gas temperature Saturated evaporating conditions 1 Product description Magnetic clutch Specifications DIRECTION OF ROTATION Clockwise viewed from clutch WEIGHT Approx 4 5 kg 10 Ib V BELT TYPE V groove A or B or V ribbed PK The above specifications may vary with the compressor 1 Product description Performance The performance data below were measured under the following conditions Compressor speed 1450 rpm Suction gas temperature 20 C Valeo TM3I performance data R134a Conditions Cooling capacity Q kW amp Power consumption P kW temp con Pd OC MPaG Ite a Valeo TM3 1 conversion factors Power consumption data at different rotation speed can be approximated with the conversion factors below Conversion factors 0 1000 1450 2000 3000 4000 4500 5000 Compressor speed rpm e Lip seal type shaft seal The compressor has a lip seal type shaft seal This type of shaft seal greatly improves the sealing of the compressor to increase its perform
13. N Do not hold the field coil by the harness 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 Armature assembly Pulley assembly Field coil 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 3 Check the field coil for a loose connector or cracked insulation 28 6 Service procedures Lead wire bushing Installer 597034 5700 mi Snap ring are Epp 9 BSS External snap ring pliers AP Ay 3 Magnetic clutch Magnetic clutch 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 8 0 10 Nem 0 8 1 0 kgf m 6 0 7 0 Ibf ft 2 Carefully place the wire harness bushing 3 Install the pulley assembly using the pulley installer 597034 5700 and a hand press 4 Install the snap ring beveled edge up using external snap ring pliers 29 6 Service procedures Magnetic clutch Drive plate Drive plate holder 5 Install the armature assembly on the 39 031 3000 driveshaft together with the original shim s Press the armature assembly dow
14. ages Imagnetic clutch Armature slips does inot engage when the compressor is running Armature does not rotate Replace the compressor if when magnetic clutch Belt slipping llocked Readjust the belt lengages Itension if the belt is loose Possible cause Measure Magnetic clutch friction Charge battery or replace Islippery surface Imagnetic clutch IThe magnetic clutch slips does not engage when the compressor is running Magnetic clutch air gap too Adjust air gap or replace wide Imagnetic clutch Low magnetic clutch voltage Charge batter Magnetic clutch friction IClean friction surface or greasy surface replace magnetic clutch Adjust the compressor installation position The magnetic clutch slips does not engage when the Belt alignment is not correct compressor is running Magnetic clutch belt is Clean or replace the belt LImagnetic clutch belt tension Adjust belt tension lis loose Smoke from The magnetic clutch does coil open or shorted Replace the magnetic clutch not engage IRefrigerant leaking Fix the refrigerant leakage uncoupled piping or piping qthen fill with refrigerant until burst having the right amount Smoke from Refrigerant oil is blowing the compressor jout 23 4 Troubleshooting A C cycle diagnosis by gauge pressure Following is a diagnosis procedure to connect gauge manifold to A C cycle me
15. ance and durability 1 Product description Dimensions TM3 I compressors with magnetic clutch Unit mm Other connecting type 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 Field coil 22 Valve plate assembly 8 Bolt 23 Gasket 9 Washer 24 Gear pump 10 Front cylinder head 25 Rear cylinder head 11 Shaft seal assembly 12 Gasket 13 Valve plate assembly 14 Suction valve 15 O ring 1 Product description Swash plate system Valeo TM3I are 10 cylinder swash plate type compressors With this type of 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 Radial bearing Drive shaft Swash plate Radial bearing Suction Suction p Compression Compression Shoe disk Ball 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 Piston Radial bearing
16. and reassembly and those for testing and running in operation MAGNETIC CLUTCH TOOLS sd Drive plate holder 597031 3000 27 For fixing drive plate Center pulley puller 597033 1700 For removing pulley Remover 597035 3820 For removing lead wire bushing Installer 597034 5700 For installing pulley 39 9 Service tools tools 32 For removing Remover 597035 0500 cylinder head and 35 i cylinder block i 32 For removing and EN NI 33 installing shaft seal Guide 597067 6100 33 For installing shaft 39 seal Test and inspection tools ol m o o For gi pressure port For low pressure port For charging refrigerant Valve assembly 597017 1120 Gas leak detector 597001 1020 For detecting gas leaks For maintaining O ring 569300 9200 nora tightness 9 Service tools Unless otherwise specified Heat treatment amp Hardness the edges are slightly chamfered pr HRC40 45 to avoid burrs and fluff 1 s45c 2 5541B D Part Name Drive plate holder Unit mm 3rd Angle Proj Surface Treatment pe Unless otherwise specified Heat treatment amp Hardness HQ HTL Heat treatment amp Hardness gg the edges are slightly chamfered E HRC 40 to 45 to avoid burrs and fluff 545C Part Name Center Pulley Puller 9 Service tools Unless otherwise specified the edges are slightly chamfered to avoid burrs and fluff Unless otherwise specified the edges are slightly chamfered to
17. asure suction and discharge pressures and analyze the defects of the cycle Operation conditions of the A C cycle for pressure measuring 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 must be another cause WR WN Discharge pressure around 1 0 1 7 MPaG 10 17 kgf cm Suction pressure around 0 13 0 20 MPaG 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 Receiver dryer is Temperature difference Replace parts clogged between inlet and outlet pipes Dryer is covered with frost Expansion valve is Expansion valve was Clean or replace part clogged covered with frost Enclosure leakage Outlet side of Replace part from 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 airis frozen up part defective Refrigerant piping is If any part between Adjust or replace the clogged or crashed the dryer an
18. avoid burrs and fluff Unit mm Section view CC Surface Treatment MFZn8TC Heat treatment amp Hardness Remover Bush Unit mm 3rd Angle Proj Surface Treatment HQ HTL EI Heat treatment amp Hardness Installer Pulle 10 Service parts 1 Compressor body service kits sets and parts Quantity OVERHAUL KIT O RING SET GASKET SET SHAFT SEAL 7077300221 po HESSE EEE EE EEE EEE O RING SET 569920 4420 15 20 O ring body front amp rear head 569300 8900 569300 4000 N GASKETSET 5699411921 9 Gasket bolt 7perset 569310 6200 n7 ENE EET SHAFT SEAL for service MEIN Shaft seal 569942 1320 SS ae a eet OTHER COMPRESSOR PARTS J 561420 2020 561410 1300 see product description Exploded view p 7 2 Oil Quantity ZXL 100PG 569900 0600 Notes 44 VALEO JAPAN TM3 I for HFC 134a use SERVICE MANUAL Version WW31 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 Valeo TM3 I Compressor for Bus Air Conditioning UU Asia 39 Sendai Kumagaya shi Saitama ken 360 0193 Japan Phone 81 0 48 539 3800 Fax 81 0 48 539 3843 Email vc oura sales valeo com Valeo TM3 I Benet High reliability Integration flexibility Great cooling capacity Enhanced performance Lower fuel consumption Compact amp robus
19. ches each cylinder valve escape groove 3 Install the rear valve plate on the rear suction valve CAUTION Do not mistake the front and rear valve plates 4 Coat the new gasket with clean compressor oil and install it on the rear valve plate 5 Coat the new gear pump with clean compressor oil and install it on the end of the drive shaft 6 Coat the new O ring with clean compressor oil and install it on the rear cylinder head 7 Install the rear cylinder head When positioning the head ensure the gear pump is inserted into the hole in the cylinder O ring AH head Gasket Valve plate assembly Suction valve Roll pins 3 8 Service procedures Gasket Valve plate assembly Suction valve Guide 597067 6100 Roll pins Oil filler plug Cylinder head 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 the spring pins CAUTION Ensure each valve matches each cylin der s valve escape groove 3 Install the front valve plate on the front suction 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
20. 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 Tightening torque M8 x 1 25 20 22 2 0 2 2 14 16 M6 x 1 0 8 0 10 0 0 8 1 0 6 7 M10 x 1 5 25 30 2 5 3 0 18 22 M10 x 1 5 14 16 1 4 1 6 10 12 M8 x 1 25 20 24 2 0 2 4 14 17 for connectors 26 6 Service procedures Magnetic clutch Drive plate holder Magnetic clutch 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 External snap ring pliers ring pliers Snap ring Position the center pulley puller 597033 1200 at the end of the driveshaft Center pulley puller Attach a suitable pulley puller to the pulley aP OLLU Z Hook the puller claws to the edge of the pulley as shown Tighten the center pulley puller bolt to remove the pulley CAUTION Do not clip the puller claws into the pulley groove to prevent pulley groove damage 6 Service procedures Magnetic clutch Lead wire bushing 5 Remove the lead wire bushing of the field coil using the remover 597035 3820 6 Remove the three field coil compressor screws Then remove the field coil CAUTIO
21. d amount 8 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 14 16 Ne m 1 4 1 6 kgf m 10 12 Ibf ft 13 Install the strainer in the suction port When the connectors are installed 14 Fit plates to the suction and discharge connections and tighten them to the specified torque Specified torque 20 24 Nem 2 0 2 4 kgf m 14 17 Ibf ft 15 Install the magnetic clutch as described on page 29 16 Run in the compressor as described on page 19 17 Perform the leak test as described on page 20 33 8 Service procedures Cylinder head Cylinder heads Front amp 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 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 597035 0500 and a mallet to remove the front cylinder head Remover 597035 0500 ee 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 the front cylinder hea
22. d and the front valve plate Valve plate assembly O ring 34 8 Service procedures Cylinder head Rear cylinder head 9 Screw two bolts into the opposite sides of the rear cylinder head and tap alternate bolts lightly with a plastic hammer to remove the head CAUTION Screw the bolts fully into the head to prevent rear head thread damage Tap lightly Gaskel 10 Remove the rear valve plate assembly and then the suction valve in that order 11 Remove and discard the O ring from the rear cylinder head 12 Remove all gasket material from the rear cylinder head and the rear valve plate Suction valve 13 Remove the gear pump from the rear cylinder head or the end of the driveshaft 3b 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 Check that none of the passages in the valve plates are blocked Valve plate Cylinder head 36 8 Service procedures Cylinder head Escape groove Reassembly 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 mat
23. d 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 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 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 MPaG 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 5 Recover refrigerant then refill with the right amount of refrigerant Clean up hand repair of fin and replacement Adjustment or replacement Evacuate air from
24. ere the bracket and mounting bolts must be installed securely Vibration resistance There must not be any resonance under 250 Hz 1 Product description Magnetic clutch 1 Voltage GREN DC 24 V The terminal voltage of the magnetic clutch must exceed 10 5 V N N The terminal voltage of the magnetic clutch DD must exceed 21 V LONG DC 12 V 2 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 idle pulley Compressor speed must not exceed the specified speed Drive pulley CAUTION Pulley ratio is the ratio of the magnetic clutch diameter to the drive pulley dia meter gt lt Magnetic clutch 3 Pulley alignment tolerance is less than 1mm 0 04 in 4 Pulley groove V groove or V ribbed 5 The belt tension must be adjusted to the tension specified by the belt maker 11 1 Product description Control switches 1 Thermo switch Capillary tube A thermo switch is necessary The following 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 Gas type thermo switch Operation temperature C F DIFF 4 or 3
25. m always use a refrigerant recovery unit made specifically for HFC 134a Compressor handling Do not strike or unecessarily 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 to circulate the oil Otherwise oil in the cylinder during 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 16 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 quantity and the degree of contamination see p 17 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 17 15 3 Handling instructions As long as it remains within the range of vision through the sight glass the oil quantity is sufficient Do not mix with other oils LENE 7 ap the container immediately Oil return operation Compressor oil mixed with refrigerant i
26. mbly 597017 1120 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 20 24 Ne m 2 0 2 4 kgf m 14 17 Ibf ft 2 Using the valve assembly 597017 1120 fill the compressor with refrigerant through the suction side raising the refrigerant pressure to at least 0 49 MPaG 5 kgf cm 71 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 compressor 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 150kPa 0 5 1 5kgf cm 7 1 21psig 20 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
27. move the shaft seal assembly using the remover 597035 4700 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 Installation 1 Clean the portion of the front cylinder head Remover where the shaft seal is to be assembled ar 2 Assemble the shaft seal on the remover Shaft seal 597035 4700 3 Coat the shaft seal well with compressor oil and install the shaft seal in the front cylinder head 4 Remove the shaft seal remover 5 Position the guide 597067 6100 on the shaft 6 Coat the new O ring with clean compressor oil and install it in the front cylinder head 7 Install the front cylinder head CAUTION Align the roll pins and tap the head light ly 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 specified torque Specified torque 25 30 Nem 2 5 3 0 kgf m 18 22 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 s 2 3 7 Service procedures Shaft seal assembly Oil filler plug 11 Fill the compressor with the specifie
28. n by hand 6 Install the center bolt and tighten to the specified torque using the drive plate holder 597031 3000 to prevent the armature assembly from the rotating Specified torque 20 22 Nem 2 0 2 2 kgf m 14 16 Ibf ft CAUTION After tightening the center bolt check that the pulley rotates smoothly 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 596541 2600 0 1 mm 0 004 in 596541 2700 0 3 mm 0 012 in Gap adjustment 596541 2800 0 5 mm 0 020 in 596541 2900 0 8 mm 0 031 in Specified clearance 0 3 0 6 mm 0 01 0 02 in 8 Run in the clutch as described on page 19 30 Service procedures Shaft seal assembl Remover 597035 0500 Press uniformly from above Remover Front cylinder head 597035 4700 3 Shaft seal 6 Shaft seal assembly Removal Remove the magnetic clutch assembly as described on page 27 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 Re
29. netic clutch Adjust air gap or replace magnetic clutch Charge batter Replace the compressor if it is locked Replace the compressor or tthe magnetic clutch Replace magnetic clutch Replace the compressor Fix the refrigerant leakage Ithen fill with refrigerant until freaching the right amount Charge the battery or replace Ithe magnetic clutch Replace the magnetic clutch after making sure it is defective Belt tension readjustment Replace the sensor after making sure it is defective IReduce the refrigerant charge until reaching the right amount Replace the condenser after making sure it is defective Replace the magnetic clutch after making sure it is defective Replace the sensor after making sure it is defective 4 Troubleshooting 2 Abnormal noise Symptom Possible cause Measure Abnormal vibration after Compressor installation bolt Increase tightening torque of turning on the A C switch is loose the loose bolts Wide gap at the attaching Improve the compressor Lportion between the attaching portion compressor and the bracket Abnormal noise from the Compressor body internal IReplace the compressor LIcompressor body component damage _ The magnetic clutch has a Magnetic clutch damage Replace the magnetic clutch backlash and slips J 9 p J Strange noise when the air gap too wide es Adjust air gap or replace magnetic clutch eng
30. roduct description encasoicesnecsoacsantoteanqeuraseacsainancdavasthvonsonteannavietians 3 NENNE 13 3 Handling instructions srrrrrnrrrrnrrrnvrrnnrrrnvnrsverenvnrnvrsenrnssvesenen 14 Maintenance precautions vresecsceascesencacesaeecesunastovsmescenestorsperceoncetrsstess 14 Vik 14 Rev 14 Compressor handling svetseisstesdesasensvatvedsnbisnceanestncdecawsagerneteosaeteetneas 15 Cie OV Ab EE 15 METT 16 od vv7v4v4v4mv4v4vvrv vev 16 MANN 17 MA 17 Rev 18 Fe MTV NM operatio EN 19 PSTN 19 MTU 19 TR GE EEE EN 20 Refrigerant charging EEE 20 Storing a repaired COMPTIESSOT renrrrenrrrnvrrrvrrrnvrrrnrrrvrrrvrrenversnrsenreen 20 4 Troubleshooting ssesecancecnonchacateocssocnstanentdawostenunttencertsnayreaaniereaedaues 21 Compressor troubleshooting rmrnrnrnnrrnvrrnvrrnnrronrronrrnnvrrnrrnnvrnnvennne 21 Compressor troubleshooting tree uu ee ees cesecesecesscesseesseesseeseeees 21 A C cycle diagnosis by gauge presSsUrfe rrrvrrvarrverrverrrrrrverrvern 24 5 TENG TOF GUC S res 26 6 Service procedures Magnetic clutch rrrnnnrrnnnrnvrrrnrnrnvennen 27 7 Service procedures Shaft seal assembly rrrnvrrnrnrnvrnnnn 31 8 Service procedures Cylinder heads rrersrrnrsnvvnsnvrnsnvrnsvvenenne 34 EE TJ SE 39 NNN 43 1 Product description Compressor Compressor TECHNOLOGY Heavy Duty Swash Plate DISPLACEMENT 313 cc 19 1 cu in per rev 700 6 000 rpm maximum peak 7 000 rpm ZXL 100 PG PAG OI
31. s 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 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 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 specifications if the ACsystemis opened for repair orreplacement of any component e g evaporator condenser or receiver drier any loss of charge refrigerant or oil is detected 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 16 3 Handling instructions e Opacity e Color change Foreign
32. t design Improved field serviceability Reduced noise and vibrations Staggering value through innovation China Europe Middle East amp Africa No 2677 Shiji Avenue Eco amp Tec Dvt 8 rue Louis Lormand ZA de l Agiot Zone 130031 Changchun Jilin PRC 78321 La Verriere France Phone 86 0 431 8499 2025 Phone 33 0 1 3013 5027 Fax 86 0 431 8499 2004 Fax 33 0 1 3461 5898 Email vc changchun sales valeo com Email vc angers sales valeo com 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 Copyright 2014 Valeo Japan CO LTD All Rights Reserved
Download Pdf Manuals
Related Search