Valeo TM55 Manual de usuario
Copyright © 2019 Valeo Japan CO., LTD. | All Rights Reserved.
SERVICE MANUAL
Valeo TM55 & TM65 Compressors
Light & Compact, Ultimate Reliability, Highest Performance
Oil fill-up plug for better
inner oil return
Lip type shaft seal providing
ultimate reliability & performance
7 double-headed pistons architecture
ensuring smooth and quiet operations
Compact & robust design enabling
easy mounting configurations
- 1 -
Foreword
The contents of the 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.
This service manual has been elaborated to help
service personnel to provide efficient and correct
service and maintenance on Valeo TM55 and
TM65 compressors for bus air conditioning.
This manual includes the operation specifications,
procedures for disassembly, reassembly, and
inspection of the compressor.
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 proper damage.
WARNINGS
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 conditioning maintenance.
MEANING OF MARKS
- 2 -
Contents
1- Product description ....................................................................... 3
Compressor speed (rpm) .................................................................. 7
Conversion factors ............................................................................. 7
2- Operation precautions ................................................................ 14
3- Handling instructions .................................................................. 15
Maintenance precautions ................................................................15
Work area ..............................................................................................15
Refrigerant handling ............................................................................15
Compressor handling .......................................................................16
Compressor removal ........................................................................16
Oil return operation .........................................................................17
Oil handling ......................................................................................17
Oil level at inclination conditions ....................................................18
Front Lifting ......................................................................................18
Lateral Inclination ............................................................................18
Oil contamination ............................................................................19
Oil check ...........................................................................................19
Replacement of components ..........................................................20
Leak test ...........................................................................................21
Refrigerant Charging ........................................................................21
Storing a repaired compressor ........................................................21
4- Troubleshooting .......................................................................... 22
Compressor troubleshooting ................................................................22
Compressor troubleshooting tree ........................................................22
A/C cycle diagnosis by gauge pressure ..............................................25
5- Tightening torques ...................................................................... 27
6- Service procedures - Magnetic clutch ........................................ 28
7- Service procedures - Shaft seal assembly ................................. 34
8- Service tools ................................................................................ 37
9- Service parts ............................................................................... 47
- 3 -
1- 1- Product description
MODEL TM55 TM65
TECHNOLOGY Heavy Duty Swash Plate
DISPLACEMENT 550 cc / 33.56 in3 per rev. 635cc / 38.75 in3 per rev.
NUMBER OF CYLINDERS 14 (7 double-headed pistons)
REVOLUTION RANGE 600-4000 rpm
DIRECTION OF ROTATION Clockwise viewed from clutch
BORE 38.5 mm (1.52 in)
STROKE 33.7 mm (1.30 in) 38.9 mm (1.53 in)
SHAFT SEAL Lip seal type
LUBRICATION SYSTEM Lubrication by gear pump
REFRIGERANT HFC-134a
OIL (QUANTITY) ZXL 100PG PAG OIL (1500 cc/0.40 gal) or POE option
CONNECTIONS
Internal Hose Diameter
Suction: 35 mm (1-3/8 in)
Discharge: 28 mm (1-1/8 in)
Suction: 35 mm (1-3/8 in)
Discharge: 35 mm (1-3/8 in)
WEIGHT 18.1kg / 39.9 lbs (w/o Clutch)
DIMENSIONS
Length - Width - Height
341 - 194 - 294 (mm)
13.4 - 7.64 - 9.33 (in)
MOUNTING Direct (side or base)
Compressor
Valeo TM55 & TM65 Application limits
- Compressor
Saturated evaporating conditions
tc
te
Saturated condensing conditions
PSIA PSIG oFMPaA MPaG oC
398 384 180 2.75 2.65 82
244 229 140 1.68 1.58 60
125 111 93 0.86 0.76 34
83 68 68 0.57 0.47 20
-20 -10 10 20 oC
0.03 0.10 0.31 0.47 MPaG
0.13 0.20 0.41 0.57 MPaA
-4 14 50 68 oF
5 14 45 68 PSIG
19 29 60 83 PSIA
tc : Condensing temperature
te : Evaporating gas temperature
- 4 -
1- Product description - Compressor
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 compressor
body.
COMP. TYPE
PART NO.
SERIAL NO.
OIL
LEAK TEST
REFRIG.
MADE IN JAPAN
TM-XX
ZXXXXXXX X
XXXXXXXXXX
XXXXXX cm3
HIGH SIDE 2.9MPaG
LOW SIDE 1.5MPaG
HFC-134a
Tip
As TM55 & TM65 compressors have the same
dimensions, the best way to differentiate them
quickly is by referring to the name plate.
Name plate
- 5 -
1- Product description - Magnetic clutch
Single level or multi-level pulleys
Housing mounted magnetic clutch.
Improved robustness to vibration
Bearing and pulley positionned to
reduce efficiently the moment of tilt
Magnetic clutch
VALEO TM55 & TM65 are available either as a compressor and magnetic clutch assembly or as a compressor
body that can be fitted with compatible magnetic clutches. The magnetic clutch design Valeo has been
promoting for more than 20 years is now gradually adopted by major market actors.
Our compressors and magnetic clutches have successfully passed the thousand hours of long validation
tests in Valeo Compressors research center laboratory. Operational excellence was 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 TM55 & TM65 compressor qualities.
Valeo TM55 & TM65 magnetic clutch
Compact and robust design
TECHNOLOGY Electromagnetic single-plate dry clutch
RATED VOLTAGE 24V DC or 12V DC
CURRENT CONSUMPTION 50 W maximum
STATIC TORQUE 250 N·m {25.5 kgf·m, 184 lbf·ft}
DIRECTION OF ROTATION Clockwise viewed from clutch
WEIGHT Approx 10~12 kg {22-27 lbs}
V-BELT TYPE V-groove (A or B) or V-ribbed (PK)
Specifications*
*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.
- 6 -
1- Product description - Connectors
Connectors
1. Fully open the shut-off valve when operating the compressor
• Unscrew the cap.
• Loose the valve spindle lock nut by 1/4 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 lock nut carefully and reinstall the cap.
2
4
5
3
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.
2
3
4
5
3. Fully close the shut-off valve when removing the compressor
• Turn the spindle in the clockwise direction until it stops.
2
3
4
5
1
1
1
Valve spindle lock nut
Cap
Spindle
Service port connector
Safety devices port
1
2
3
4
5
Valve spindle lock nut
Cap
Spindle
Service port connector
Safety devices port
1
2
3
4
5
Valve spindle lock nut
Cap
Spindle
Service port connector
Safety devices port
1
2
3
4
5
- 7 -
1- Product description - Performance
Valeo TM55 & TM65 conversion factors
The performance data below were measured under the following conditions:
• Compressor speed: 1450 rpm
• Suction gas temperature: 20°C
Conditions Cooling Capacity Q and Power Consumption P
Cond.
temp (oC )
Pd
(MPaG)
Evap temp
(oC ) -10 -5 0 5 10 12.5
Ps (MPaG) 0.10 0.15 0.19 0.24 0.32 0.35
40 0.91 Q (kW) 17.29 22.96 28.21 33.92 42.18 45.71
P (kW) 6.30 7.02 7.53 8.10 8.68 8.90
50 1.21 Q (kW) 15.16 20.21 24.24 29.31 37.58 40.37
P (kW) 6.83 7.76 8.39 9.06 9.90 10.11
60 1.58 Q (kW) 12.66 17.30 20.80 25.28 32.10 34.56
P (kW) 7.35 8.43 9.17 9.95 11.02 11.35
Valeo TM-65 performance data (R134a)
Conditions Cooling Capacity Q and Power Consumption P
Cond.
temp (oC )
Pd
(MPaG)
Evap temp
(oC ) -10 -5 0 5 10 12.5
Ps (MPaG) 0.10 0.15 0.19 0.24 0.32 0.35
40 0.91 Q (kW) 14.73 19.68 23.88 29.30 37.23 40.31
P (kW) 5.31 5.96 6.39 6.77 7.21 7.36
50 1.21 Q (kW) 12.75 17.52 21.06 25.58 32.97 35.54
P (kW) 5.80 6.59 7.09 7.63 8.32 8.48
60 1.58 Q (kW) 10.53 14.42 17.60 21.39 28.16 30.65
P (kW) 6.28 7.21 7.84 8.52 9.38 9.63
Valeo TM-55 performance data (R134a)
The performance data at different rotation speed can be approximated with the conversion factors
below.
1000
0.0
0.5
1.0
1.5
2.0
2.5
3.0
02000 3000 4000
P
Q
Compressor speed (rpm)
Conversion factors
1450
- 8 -
1-Product description - Dimensions
TM55 & TM65 compressors
12-M12x1.75,Dp26
6-M6x1.0,Dp13
PCD ∅ 90
Este manual sirve para los siguientes modelos
1
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