Valeo TM31 Manuale utente

SERVICE MANUAL

Valeo TM31 Compressor

- 1 -

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.

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 conditioner maintenance.

MEANING OF MARKS

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.

- 2 -

Contents

1- Product description ....................................................................... 3

2- Operation precautions ................................................................ 13

3- Handling instructions .................................................................. 14

Maintenance precautions ................................................................14

Work area ..............................................................................................14

Refrigerant handling ............................................................................14

Compressor handling .......................................................................15

Compressor removal ........................................................................15

Oil return operation .........................................................................16

Oil handling ......................................................................................16

Oil contamination ............................................................................17

Oil check ...........................................................................................17

Replacement of components ..........................................................18

Running-in operation .......................................................................19

Compressor running-in .........................................................................19

Magnetic clutch running-in ..................................................................19

Leak test ...........................................................................................20

Refrigerant charging ........................................................................20

Storing a repaired compressor ........................................................20

4- Troubleshooting .......................................................................... 21

Compressor troubleshooting ...........................................................21

Compressor troubleshooting tree ...................................................21

A/C cycle diagnosis by gauge pressure..........................................24

5- Tightening torques ...................................................................... 26

6- Service procedures - Magnetic clutch ........................................ 27

7- Service procedures - Shaft seal assembly ................................. 31

8- Service procedures - Cylinder heads .......................................... 34

9- Service tools ................................................................................ 39

10- Service parts ............................................................................. 43

- 3 -

1-Product description - Compressor

Compressor

MODEL TM31

TECHNOLOGY Heavy Duty Swash Plate

DISPLACEMENT 313 cc (19.1 cu in) per rev.

NUMBER OF CYLINDERS 10

REVOLUTION RANGE 700-6,000 rpm (maximum peak : 7,000 rpm)

DIRECTION OF ROTATION Clockwise viewed from clutch

BORE 36 mm (1.42 in)

STROKE 30.7 mm (1.21 in)

SHAFT SEAL Lip seal type

LUBRICATION SYSTEM Lubrication by gear pump

REFRIGERANT HFC-134a

OIL (QUANTITY) ZXL 100 PG PAG OIL (DH-PS): 500 cc ( 30.5 cu in)

WEIGHT 9.5 kg (21 lb) (w/o Clutch w/o oil)

DIMENSIONS (with clutch)

Length - Width - Height

278.5 - 143 - 178 (mm)

10.94 - 5.63 - 7 (in)

MOUNTING Direct (side or base)

Valeo TM31 Application limits for HFC-134a

Saturated evaporating conditions

Saturated condensing conditions

PSIA PSIG oFMPaA MPaG oC

358 343 171 2.47 2.37 77

244 229 140 1.68 1.58 60

191 177 122 1.32 1.22 50

100 85 79 0.69 0.58 26

-17 -10 5 14 oC

0.05 0.10 0.25 0.37 MPaG

0.15 0.20 0.35 047 MPaA

1 14 41 57 oF

7 14 36 54 PSIG

22 29 51 69 PSIA

tc : Condensing temperature

te : Evaporating gas temperature

- 4 -

※The above specifications may vary with the compressor.

TYPE Electromagnetic single-plate dry clutch

RATED VOLTAGE 24V DC or 12 V DC

POWER CONSUMPTION 48 W maximum

STATIC TORQUE 78 N·m {8.0 kgf·m, 58 lbf·ft}

DIRECTION OF ROTATION Clockwise, viewed from clutch

WEIGHT Approx 4.5 kg {10 lb}

V-BELT TYPE V-groove (A or B) or V-ribbed (PK)

1- Product description - Magnetic clutch

Specifications*

- 5 -

1- Product description - Performance

The performance data below were measured under the following conditions:

• Compressor speed: 1450 rpm

• Suction gas temperature: 20oC

Conditions Cooling capacity Q (kW) & Power consumption P (kW)

Cond temp

(oC )

(MPaG)

Evap temp

(oC ) 12.5 10 7.5 5 0 -5 -10

Ps (MPaG) 0.35 0.32 0.28 0.24 0.19 0.15 0.10

40 0.91 P (kW) 4.04 3.94 3.82 3.74 3.49 3.20 2.88

Q (kW) 22.64 20.61 18.65 17.57 13.68 10.56 8.19

50 1.21 P (kW) 4.59 4.48 4.34 4.18 3.84 3.47 3.08

Q (kW) 21.22 18.70 16.54 14.85 11.66 9.06 6.93

60 1.58 P (kW) 5.18 5.00 4.79 4.59 4.17 3.72 3.27

Q (kW) 17.25 15.46 13.78 12.32 9.69 7.46 5.65

Valeo TM31 performance data (R134a)

Valeo TM31 conversion factors

Power consumption 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

• 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 performance and durability.

4500 5000

1450

Compressor speed (rpm)

Conversion factors

- 6 -

1- Product description - Dimensions

Unit: mm

Other connecting type

TM31compressors with magnetic clutch

45°

30°

∅

158

∅

156 (effective diameter)

48 48

7999

112

38.5

22 22

Approx 178

4-M8x1.25

21 42

167

116

Approx 244

Approx 278.5

12-M10x1.5

2-M8x1.25

7.7

0.3~0.6

143

- 7 -

1- Product description - Exploded view

1. Center bolt

2. Armature assembly

3. Adjusting shim

4. Snapring

5. Pulley assembly

6. Screw

7. Field coil

8. Bolt

9. Washer

10. Front cylinder head

11. Shaft seal assembly

12. Gasket

13. Valve plate assembly

14. Suction valve

15. O-ring

16. Cylinder shaft assembly

17. Oil filler plug

18. O-ring

19. Strainer (option)

20. O-ring

21. Suction valve

22. Valve plate assembly

23. Gasket

24. Gear pump

25. Rear cylinder head

- 8 -

1- Product description - Swash plate system

Valeo TM31 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.

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.

Drive shaft Radial bearing Radial bearingPiston

Thrust bearing

Swash plate

Radial bearing

Thrust bearing

Suction

Compression

Suction

Ball PistonShoe disk

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.

Indice

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