TM21 Service manual
Contents
1. 30 6 Service procedures Magnetic clutch 5 Remove the field coil s lead wire bushing Remover using the remover 597035 3820 pease 6 Remove the three field coil compressor screws Then remove the field coil D CAUTION 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 both the Armature assembly Pulley assembly Field coil pulley and armature must be replaced The contact surfaces 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 31 6 Service procedures Magnetic clutch External snap ring pliers 32 Magnetic clutch Installation 1 N Install the field coil on the compressor with the harness on top and tighten the mounting screws to the specified torque Specified torque 4 6 N m 0 4 0 6 kgf m 3 0 4 4 Ibf ft Carefully place the wire harness bushing Install the pulley assembly using the pulley installer 597034 3301 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 Insta2. Pipping connection procedure Union Nut CORRECT on INCORRECT A Damage CH g Gnawing at pipe end Piping precautions 1 Position the O Ring against the bulge in the pipe when connecting hoses and pipes 2 Coat the piping connections and the O rings with PAG oil CAUTION Always use the specified oil for HFC134a systems to coat the O rings 3 Fitthe nuts and unions tightly against the base of the companion pieces then hand tighten the nut as much as possible Then tighten to the specified torque ADVICE Valeo Compressors recommends the following hose sizes INTERNAL DIAMETER Suction 12 5 mm 1 2 inch Discharge 8 mm 5 16 inch 22 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 24 25 for the appropriate counter measure Most of the malfunc
3. SERVICE MANUAL Valeo TM21 Compressor added il Copyright 2015 Valeo Japan CO LTD All rights reserved Foreword This service manual has been elaborated to help ser The contents of this manual including illustrations vice personnel to provide efficient and correct service drawings and specifications were the latest available and maintenance on the TM21 model compressors at the time of printing for HFC 134a for automotive air conditioning Valeo Japan reserves the right to make changes in This manual includes the operation specifications specifications and procedures at any time without procedures for disassembly reassembly and notice inspection of the compressor 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 Maintenance must be properly done to avoid serious injury risks CAUTION 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 Contents T EIERE eege 3 lh e EE 12 3 Handling Imst
4. Operate the A C switch through the ON OFF cycle at least 50 times ON for 10 seconds and OFF for 10 seconds 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 fol lows 1 Install the discharge and suctions caps on the compressors 2 Fill the compressor with refrigerant gaz through the suction port raising the pressure at least to 0 4 MPaG 55 3 psig 3 Check the compressor for leaks using a leak detector 597001 1020 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 49 150 kPa 0 5 1 5 kgf cm 7 1 21 psi 1 9 3 Handling Instructions 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 Initial Leak Check Using the leak detector check the system connec tions for leaks As the system pressure is not yet high only large leaks can be detected at this time 20 3 Handling Instructions Installation position The compressor should be installed in the vehicle within the range shown on the left han
5. 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 Gasoline inflammables 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 protective 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 13 3 Handling instructions Do not release refrigerant into the air on C000 Oil return operation Refrigrant recovery Compressor removal Oil inspection 1 4 2 Do not release refrigerant into the air Althoug
6. 035 2501 into the shaft seal and turn it untill it hits the shaft seal case Then pull the remover up to remove the shaft seal 7 Services procedures Shaft seal assembly Guide pe a 59067 1102 4 Shaft seal Remover 59035 5520 Guide 59067 1102 35 1 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 Before installation refer to Inspection p 31 Clean the sealed section of the front cylinder head Coat the new shaft seal and the front cylinder head with clean compressor oil If the slip faces are dirty clean them with thinners and after drying the clean faces apply clean compressor oil to them Fit the guide 597067 1102 onto the end of the drive shaft Insert the shaft seal through the guide into the front cylinder head Install the shaft seal as far as possible into the front cylinder head using the installing end of the remover 597035 5520 Remove the guide 597067 1102 from the drive shaft 7 Services procedures Shaft seal assembly Internal snapring pliers 6 Install the snap ring using internal snap ring pliers Press the snap ring using the installing end of the remover 597035 5520 until a click is heard Shaft sea
7. 2 Notes 43 Notes 44 Notes 45 VALEO JAPAN TM21 for HFC 134a SERVICE MANUAL Version WW21 15006 02EN Published by VALEO JAPAN CO LTD Copyright 2015 VALEO JAPAN CO LTD For any inquiry regarding the present service manual contact us at vc oura sales valeo com 46 Valeo TM21 Compressor Valeo TM21 Ben High reliability 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 III RUN added Il Asia China Europe Middle East amp Africa Americas 39 Sendai Kumagaya shi No 2677 Shiji Avenue Eco amp Tec Dvt 8 rue Louis Lormand ZA de l Agiot 2520 Esters Blvd 100 Saitama ken 360 0193 Japan Zone 130031 Changchun Jilin PRC Le Mesnil Saint Denis Cedex Dallas TX 75261 United States Phone 81 0 48 539 3800 Phone 86 0 431 8499 2025 78321 La Verriere Phone 1 972 456 1077 Fax 81 0 48 539 3843 Fax 86 0 431 8499 2004 Phone 33 0 1 30 13 50 27 Fax 1 972 456 1090 Email vc oura sales valeo com Email vc changchun sales valeo com Email vc angers sales valeo com Email vc dallas sales valeo com Copyright 2015 Valeo Japan CO LTD All Rights Reserved
8. ansion 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 and the part compressor is clogged or crashed the low side pressure becomes vacuum 27 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 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 19 0 29 MPaG 3 4 kgf cm Appreciable temperature difference at the clogged location Discha
9. charge of compressor oil Valeo Each compressor is delivered with the specified COMP TYPE TMXX quantity of compressor oil depending on the PART NO XXXXXXX X type of air conditioning system SERIAL Ge Ze A label describing the amount of compressor oil is LEAR TEST EE attached to the compressor l REFRIG HFC 134a MADE IN JAPAN Opacity Oil contamination Color change Foreign substances Metal filings 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 noth ing wrong with the compressor or its method of use Inspect the extracted oil for any of the fol lowing e 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 page 15 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 Charge specified quantity of Ow Deiere connertors compressor oil 4 Check the oil for contamination 5 Fill the compressor with the specif
10. d figure If it is installed outside this range the compressor will be adversely affected This compressor is equipped with a pressure feed lubrication system which cannot function if the compressor is installed outside this range If the compressor is installed outside the range shown on the left hand figure any or all warranties may be rendred void Installation precautions The new compressor is filled with the specified quantity of compressor oil and nitrogen gas N When mounting the compressor on the vehicle please follow as below 1 Loosen the discharge side connector s cap and gently release nitrogen gas N from the com pressor 2 Turn the magnetic clutch s armature plate sev eral times by hand to distribute the oil which has settled in the cylinders 3 When installing the compressor in service sys tem the compressor should be installed after adjusting the amount of oil referring to oil check p 16 CAUTION Do not let the oil escape 21 3 Handling Instructions O ring positions CORRECT INCORRECT INCORRECT Giles MI O ring Pipe bulge Apply oil thoroughly to these areas Fa Piping connection Compressor condenser connection
11. etic clutch does not engage Possible cause Compressor internal part damage Refrigerant shortage Lead wire short circuit or wiring connector not seated properly Thermal fuse if provided opened by high heat i The magnetic clutch engages Belt slipping Compressor internal part damage or magnetic clutch damage Bolt drop off Armature drop off E then fill with refrigerant until i reaching the right amount Refrigerant shortage Magnetic clutch friction surface slipping Loose connection of the magnetic clutch electrical i circuit Magnetic clutch belt slipping Defective thermostatic switch 24 Magnetic clutch damage Magnetic clutch air gap too wide i Low magnetic clutch voltage Measure Replace the compressor Fix the refrigerant leakage i then fill with refrigerant until i reaching the right amount Replace the lead wire if it is defective Repair or replace the magnetic clutch Adjust air gap or replace magnetic clutch Check the voltage of batter Service system and replace the compressor Replace the compressor if it is locked Replace the compressor or the magnetic clutch Replace magnetic clutch Replace the compressor Fix the refrigerant leakage Check the voltage of battery or replace the magnetic i clutch Replace the magnetic clutch after making sure it is i Idefective Belt tension readjustment Replace
12. g Jout Possible cause Compressor installation bolt is loose i 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 Islippery surface Belt slipping e Possible cause Magnetic clutch air gap too wide Low magnetic clutch voltage H Magnetic clutch friction Igreasy surface i Belt alignment is not correct Magnetic clutch belt tension lis loose i Coil open or shorted Refrigerant leaking uncoupled piping or piping burst Refrigerant blowing from the high pressure relief valve i due to excess of refrigerant 26 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 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 i installation position Magnetic clutch belt is greasy j Clean or replace the belt Adjust belt tension Replace the magnetic clutch Fix the refrigerant leakage i then fill wit
13. h HFC 134a is not subject to CFC regulations it can have an effect on global warming and so should not be released into the air When removing refrigerant from the air conditioner system always use a refrigerant recovery unit made 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 by hand 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 15 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 16 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 16 3 Handling instructions Do not mix wi
14. h 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 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 shall be another cause Ui WN Discharge pressure around 0 9 1 6 MPaG 10 17 kgf cm2 Suction pressure around 0 03 0 10 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 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 Exp
15. ied amount of oil through the Suction port see illustration on the left 1 6 3 Handling instructions Current Compressor compressor is replaced unit cm amp cc is kept H Amount to remove from new compressor Charging amount Amount recovered Factory oil charge Same as recovered 180 amount recovered Current Compressor is kept Compressor is unit cu in replaced Amount to remove from new compressor Charging amount Amount recovered Factory oil charge 10 9 amount recovered Same as recovered Wi W o x Wo d 30cm3 NS d 1 7 CAUTION The specified oil quantity differs depending on the type of air conditioner 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 will remain as an oil film on the inside of the compressor and the system components Therefore refer to the table on the left when recharging the compressor with oil Excess oil adversely affects the cooling capacity and the compressor 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 com pressor Component mounted Amount of oil 50 cm 3 cu in 30_ cm 6 cu in 30 cm 1 8 cu in After installing
16. inal 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 The 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 operation 3 Always charge the A C system with the specified quantity of refrigerant 4 Keep the compressor clear of water projection Caution u Le while cleaning the vehicle 12 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
17. its label XXXXXXX X SERIAL NO XXXXXXXXXX The total amount of oil your air conditioning system ZXL 100PG 180 cm3 S GE NEEN requires is provided by the system designer or LOW SIDE 1 5MPaG supplier REFRIG HFC 134a MADE IN JAPAN Compressor 1 The direction of rotation is clockwise or counter clockwise Operation condition table Condition 2 The compressor must be operated under the conditions shown in the operation condition Surrounding under 120 C 248 F table on the left temperature Minimum 700 r min CAUTION Speed Maximum 6000 r min The A C cycle components must be Continuous 6000 r min designed so that the pressure in the cycle 5 Maximum 2 07 MPaG does not exceed 2 07 MPaG 22 1 kgf cm2 eee 22 1 kgf cm2 299 psig 299 psig 4 Inclination limit at installation The compressor must be installed on the vehicle within the range shown to the left 1 0 1 Product description General Magnetic clutch Idle pulley Drive pulley 11 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 Magnetic clutch 1 Voltage DC 24 V The terminal voltage of the magnetic clutch must exceed 21 V DC 12 V The term
18. l Guide Snapring Sw H Note 1 When installing the snap ring the round edge of the snap ring must face downward as shown on the left hand figure 2 Check the snap ring is properly installed as shown on the left hand figure Install the oil drain plug with a new O ring thinly coated with clean compressor oil and tighten it to the specified torque Specified torque 13 15 N m 1 3 1 5 kgf m 9 6 11 Ibf ft 36 8 Services procedures Cylinder heads Bolts Remover 597035 0500 Cylinder heads Front amp Rear Disassembly 1 Ze 3 Gasket O ring Front cylinder head Y suction valve Valve plate 37 Remove the magnetic clutch assembly as described on page 30 Remove the drain 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 mallet to remove the front cylinder head Remove the O ring from the front cylinder head and then remove all the gasket material from the cylinder head Remove the valve plate and suction valve from the cylinder shaft assembly and then remove all the gasket material from the valve plate 8 Services procedures Cylinder heads 7 To remove the rear cylinder head alternately tap
19. ll the snap ring beveled edge up using external snapring pliers 6 Service procedures Magnetic clutch Drive plate Adjusting shims 5 Installthearmature assembly on the driveshaft together with the original shim s Press the armature assembly down by hand 6 Install the center bolt and tighten the bolt to the specified torque using the drive plate holder 597031 2600 to prevent armature assembly from the rotating Specified torque 12 14 N m 1 2 1 4 kgf m 8 9 10 3 Ibf ft CAUTION After tightening the center bolt check that the pulley rotates smoothly Thickness gauge Gap adjustment 0 3 0 7 mm 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 1900 0 1 mm 0 0039 in 596541 2000 0 3 mm 0 0118 in 596541 2100 0 5 mm 0 0197 in Specified clearance 0 3 0 7 mm 0 01 0 03 in 8 Run in the clutch as described on page 18 33 7 Services procedures Shaft seal assembly Remover 59035 2501 34 Shaft seal assembly Removal 1 Remove the magnetic clutch assembly as described on page 30 2 Remove the drain plug and then drain the oil 3 Remove the five bolts securing the heads 4 Remove the snapring using internal snapring pliers 5 Insert the remover 597
20. n the rear valve plate Coat the new O ring with clean compressor oil and install it on the rear cylinder head Install the rear cylinder head 8 Services procedures Cylinder heads E Front cylinder head 40 Front cylinder head 1 2 1 11 12 13 Place the cylinder shaft assembly on the bench with the front side up Install the front suction valve so that it matches the pins CAUTION Ensure each valve matches each cylin der s valve escape groove Install the front valve plate on the front suction valve Coat the new gasket with clean compressor oil and install it on the front valve plate Position the guide on the shaft Coat the new O ring with clean compressor oil and install it on 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 Mount the new gaskets on the through bolts Insert the five through bolts from the front cylinder head side and tighten them to the specified torque Each bolt should be gradually tightened in three or more stages to ensure the specified torque The bolts should be tightened in the order shown on the left hand figure Specified torque 20 24 N m 2 0 2 4 kgf m 14 8 17 7 lbf ft Install the oil drain plug with a new O ring thinly coated with clean compressor oil and tighten it t
21. o the specified torque Specified torque 13 15 N m 1 3 1 5 kgf m 9 6 11 Ibf ft Fill the compressor with the specified amount of clean compressor oil through the suction side connector Install the magnetic cluch p 32 Run in compressor p 18 Carry out the leak test p 19 9 Service tools Compressor tools page 9 Shaft Seal Remover 597035 5520 For removing cylinder head and cylinder block For removing shaft seal 597067 1102 For installing shaft seal Drive plate holder 597031 2600 29 To fix armature Test and inspection tools page SS 41 10 Service parts 1 Compressor body service kits sets and parts Quantity OVERHAUL SET O RING SET GASKET SET SHAFT SEAL 566211 9520 TRUST BEARING EE RING SET 566211 9720 gt __ O ring body front amp rear head _ 569300 3100 n 2 n 1 n 1 2 O ring Fitting 569300 2800 n GASKET SET 566211 9820 Gasket front and rear head 566128 8000 _ Gasket bolt 596174 0900 SHAFT SEAL SET 569942 1120 __ Shaft seal assembly 569200 3820 THRUST BEARING SET 596196 0520 E Thrust bearing 566196 0200 OTHER COMPRESSOR PARTS K ee ee Valve plate assy front 566018 3820 Valve plate assy rear 566018 3920 Suction valve 566107 1700 See Product description Exploded view p 7 except for Trust bearing 2 0il Item Quantity _ ZXL 100PG 250 cc 569900 0600 250cc 4
22. rge and suction pressures balance immediately after the compressor stops Defective compression of compressor 28 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 7 Fittings and ports 3 4 16UNF Maximum torque 27 2 8 20 7 8 14UNF Maximum torque 37 3 8 27 1 14UNS Maximum torque 47 4 8 35 29 6 Service procedures Magnetic clutch Drive plate holder Magnetic cl utch 597031 2600 4 Removal L 1 Remove the center bolt using the drive plate holder 597031 2600 to prevent armature assembly rotation 2 Remove the drive plate using the drive plate puller Remove the shims from the compressor drive plate or drive shaft 3 Remove the snapring using external snapring pliers Snap ring External snap ring pliers 4 Position the center pulley puller at the end of the driveshaft 5 Attach a suitable pulley puller to the pulley Pulley puller Hook the puller claws to the edge of the a pulley as shown 6 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
23. ruchons cc cecessesesceseesesseseeccseeseecesecseesesessseeesesseeeens 13 Maimienance pecat eegener 13 Compressor Tu ue ca vecencaivnntavsuisdacsenecsansurdderausdectaundeauaiiasendauetenmasendadeas 14 Compressor TEMNON EE 14 OU return oper AW EE 15 ln Ciel 15 REENEN 16 8 Eu 1 v E 16 Replacement of components 1 ac ecria icmransatiitm irr 17 IEMA Operaio ege 18 Ka 19 A 80 0 23s NOONG sesoses i aaa an a aN 23 5 Montering Keren esine EE 29 6 Service procedures Magnetic EIORENeen Geteste 30 7 Services procedures Shaft seal assembhy 34 8 Services procedures Cylinder bheads 37 Cylinder earen dene a 37 E le 39 g Service Eege 41 TO CNE DANS perra R E 42 Saturated condensing conditions 1 Product description Compressor Compressors MODEL TECHNOLOGY DISPLACEMENT NUMBER OF CYLINDERS REVOLUTION RANGE 700 6000 rpm DIRECTION OF ROTATION Clockwise or counter clockwise depending on clutch type BORE 32 mm 1 26 in Length Width Height 7 8 5 5 8 in MOUNTING Direct side or base Valeo TM2I Application limits for HFC 134a tc Condensing temperature te Evaporating gas temperature Saturated evaporating conditions 1 Product description Magnetic clutch Magnetic clutch VALEO TM21 is available either as a compressor and magnetic clutch assembly or as a compressor body that cus
24. scription Dimensions TM21 Approx 230 23 5 CLUTCH GAP 0 3 0 7 145 110 5 Torque 5 1 Nm 128 0 2 1 Product description Exploded view 9 Center bolt Armature assembly Adjusting shim Snap ring Pulley assembly Screw Field coil Bolt Gasket 10 Shaft Seal assembly 11 Front cilynder head 12 O Ring 13 Gasket 14 Valve plate assembly 15 Suction valve 16 Pin 17 Cylinder shaft assembly 18 Valve plate assenbly 19 Gasket 20 Rear cylinder head 21 O ring 22 Plug 23 O ring 24 Relief Valve 25 O ring 26 Shipping plate 27 Bolt 1 Product description Performance The performance data below were measured under the following conditions Compressor speed 1450 rpm Suction Gas Temperature 20 C Cooling capacity Q kW amp Power consumption P kW nein pao 5 0 s 0 js Temperature Ps MPaG am ao sae 650 ee ors 1192 ean 250 266 297 326 350 367 Valeo TM21 conversion factors The performance data at different rotation speed can be approximated with the conversion factors below 3 5 3 0 P 2 5 e 2 0 Z I r I Ee 1 5 d Ae 7 0 5 0 0 i 0 1000 1450 2000 3000 4000 5000 Conversion factors Compressor speed rpm 1 Product description Swash plate s
25. th other oils 15 Oil return operation Compressor oil mixed with refrigerant is circulating in the air conditioning system Perform the oil return operation to return this oil to the compressor before removing components from the system 1 Open the doors and windows and operate the blower motor at maximum speed 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 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 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 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 3 Handling instructions Full
26. the thermostatic switch after making sure it is defective 4 Troubleshooting Cool blow comes out only from time to time 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 Excess of refrigerant Condenser fan failure Loose connection of the magnetic clutch electrical circuit Defective thermostatic i switch 25 Measure Reduce the refrigerant charge until reaching the i right amount Replace the condenser after making sure it is defective Replace the magnetic clutch after making sure it is i defective i Replace the thermostatic switch after making sure it is defective 4 Troubleshooting 2 Abnormal noise 3 Smoke Smoke from the compressor Symptom JAbnormal vibration after turning on the A C switch Abnormal noise from the L compressor 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 Refrigerant oil is blowin
27. the two projections on the front head using the remover 5970350500 and mallet H 8 Remove the O ring from the rear cylinder S head and then remove all the gasket material O from the rear cylinder D E Rear cylinder e head O ring Gasket 9 Remove the valve plate and suction valve from cylinder shaft assembly then remove all NVa the gasket material from the valve plate XK valve plate ba Suction valve 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 passengers in the valve Front cylinder head Valve plate plates are blocked 38 8 Services procedures Cylinder heads Esca pe groove Suction valve Suction valve Rear cylinder head Gasket Reassembly Rear cylinder head 1 2 39 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 plate on the rear suction valve CAUTION Do not mistake the front valve plate for the rear one Coat the new gasket with clean compressor oil and install it o
28. these component parts check the compressor oil Refer to page 16 3 Handling instructions Flexible hose gt 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 2 33 High pressure connector Low pressure connector 1 8 Check that the compressor contains the speci fied amount of oil Interconnect the suction fitting and the dis charge fitting with the flexible hose Install the high pressure connector and the low pressure connector to the ports and tight en the bolts to the specified torque Connect the two connector ports using a flex ible hose Run the compressor at 500 rpm for 30 min utes to 60 minutes This operation may be performed by an electric motor or the engine of an automobile Replace the oil Repeat the leak test CAUTION While the compressor is being run in in step 3 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 2 Install the clutch on the compressor Install the compressor on the test bench and operate the compressor by running the sys tem Maintain the compressor speed at 700 rpm
29. tion 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 26 27 Compressor troubleshooting tree 1 Insufficient cooling capacity A Compressor is not running B Compressor is running C Compressor runs intermittently A Abnormal noise from compressor 2 Abnormal noise B Abnormal noise from magnetic clutch C Belt slipping noise A Magnetic clutch friction surface slipping B Magnetic clutch belt slipping C Smoke from magnetic clutch D Smoke from compressor 23 4 Troubleshooting 1 Insufficient cooling capacity No cool blow coming out No cool blow coming out Symptom Magnetic clutch slips when l turning on the A C switch i Low pressure cut switch operates see p 26 27 The magnetic clutch slips or does not engage when the compressor runs but the armature does not rotate Belt run off the pulley Center bolt is loose Center bolt is missing Compressor is running i normally No difference of temperature between discharge side and suction side see p 26 27 The magnetic clutch slips or does not engage when the compressor is running Belt slipping The magn
30. tomers 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 the Valeo Compressors research center laboratory Operational excellence was demonstrated during hot season testing on the field under challenging climates in the most stressful conditions 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 TM21 compressor qualities Specifications TM21 DIRECTION OF ROTATION Clockwise or counter clockwise depending on clutch type WEIGHT Approx 3 0 kg 6 Ibs V BELT TYPE V groove A or B or V ribbed PK Please note that the maintenance procedures introduced in this service manual apply only to magnetic clutches provided by Valeo 1 Product description Name Plate Name plate To ensure that the compressor operates smoothly Valeo respect carefully the indications written on the ss name plate OMP TYPE TM21 ART NO XXXXXXX X ERIAL NO XXXXXXXXXX IL ZXL 100PG 180 cm LEAKTEST LOW SIDE 1 5MPaG EFRIG HFC 134a MADE IN JAPAN 1 Product de
31. ystem Valeo TM21 are 10 cylinder swash plate type compressors 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 by a swash plate to perform suction compression and discharge Radial bearing 230 Suction Suction Tr Compression Compression gj 7 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 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 The rotation of the swash plate 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 General Full charge of compressor oil Each compressor is delivered filled with a specified quantity of compressor oil as described on
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