Valeo TMX Bedienungsanleitung
SERVICE MANUAL
Valeo TMX
Copyright 2020 Valeo, LTD. All rights reserved.
2
Foreword
This service manual has been elaborated to help service personnel to provide efficient and correct
service and maintenance on the TMX model compressor (for HFC-134a and HFO-1234yf) for
commercial vehicles 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 reserves the right to make changes in specifications and
procedures at any time without notice.
VALEO INC.
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.
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.
WARNINGS
MEANING OF MARK
1. Product description
2. Operation precautions
3. Handling instructions
3.1. Maintenance precautions
3.1.1. Working area
3.1.2. Refrigerant handling
3.2. Compressor handling
3.3. Compressor removal
3.4. Oil Management
3.4.1. Oil return operation
3.4.2. Oil handling
3.4.3. Oil contamination
3.4.4. Oil specification
3.4.5. Oil check
3.5. Running-in operation
3.5.1. Compressor running-in
3.5.2. Magnetic clutch running
3.6. Leak test
3.7. Refrigerant charging
3.8. Installation precautions
3.9. Piping precautions
4. Troubleshooting
4.1. Compressor troubleshooting
4.2. Compressor troubleshooting tree
4.3. A/C cycle diagnosis by gauge pressure
5. Service procedures : Magnetic Clutch
5.1. Exploded view
5.2. Removal
5.3. Inspection
5.4. Installation
6. Service tools
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Contents
P3
P8
P9
P9
P10
P10
P11
P11
P12
P12
P12
P13
P14
P15
P15
P16
P17
P18
P19
P19
P24
P26
P27
P28
P29
P31
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1 - PRODUCT DESCRIPTION - COMPRESSOR
TECHNOLOGY Heavy Duty Fixed Piston Swash Plate Type Compressor
DISPLACEMENT 156.7cc
NUMBER OF CYLINDERS 10 (5 double-headed pistons)
DIRECTION OF ROTATION Clockwise
BORE 30.5 mm (1.2 in)
STROKE 21.4 mm (0.84 in)
SHAFT SEAL Lip seal type
LUBRICATION SYSTEM Splash lubrication
REFRIGERANT R134a or R1234yf
OIL TYPE / AMOUNT *VC100YF PAG OIL / 130 cm3
RATED VOLTAGE 12V DC
* Customer can order Valeo service oil package ➝ Part number: T428727
(1 CASE = 6 x 250 cc can)
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1 - PRODUCT DESCRIPTION - COMPRESSOR
Compressor
1. The compressor must be operated within the green area shown on Table 1.
2. Inclination limit at installation The compressor must be installed on the vehicle within the range
shown on Table 2.
Table 2
-21 -2 16 ℃
0.10 0.18 0.38 MPaG
0.20 0.28 0.48 MPaA
-6 28 61 ℉
14 25 58 PSIG
29 40 69 PSIA
Table 1
Tc
Te
PSIA PSIG ℉MPaA MPaG ℃
450 435 190 3.10 3.00 88
244 229 140 1.68 1.58 60
160 145 109 1.10 1.00 43
100 85 88 0.69 0.59 31
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1 - PRODUCT DESCRIPTION - PERFORMANCE
The performance data below were measured under the following conditions:
●Discharge Pressure: Pd = 1.52 MPaG
●Suction Pressure: Ps = 0.18 MPaG
●Subcooling temperature: SC = 5°C
●Super heat temperature: SH = 10°C
Valeo TMX performance data table (R134a) :
Valeo TMX performance data graph (R134a) :
Nc (r/min) 1000 1500 2000 2500 3000
Vol. Eff. (%) 72.9 73.8 72.2 69.8 66.2
Capacity (kW) 3.3 5.1 6.6 8.0 9.1
Power (kW) 1.4 2.1 2.9 3.7 4.5
COP 2.4 2.4 2.3 2.2 2.0
Capacity
Vol. eff.
Power
COP
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1 - PRODUCT DESCRIPTION - SWASH PLATE SYSTEM
Valeo TMX is a 10 cylinders swash plate type 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.
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.
Piston Drive System
Suction
Compression
Suction
Compression
Shoe Piston
Drive shaft Radial bearing Thrust bearing
Swash Plate
Piston
Radial bearing
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2 - OPERATION PRECAUTIONS
Preventive Maintenance
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. Do not allow a compressor that has not been
used for a long period to become wet.
4. Always charge the A/C system with the
specified quantity of refrigerant.
5. Keep the compressor clear of water projection
while cleaning the vehicule
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3 - HANDLING INSTRUCTIONS
Maintenance precautions
Working 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.
●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).
CAUTION!
Refrigerant itself is not harmful but excessive
accumulation in a closed area can cause
oxygen deficiency.
WARNING!
Contact with flame and high temperatures can
generate toxic gases.
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3 - HANDLING INSTRUCTIONS
Refrigerant handling
1.Do not misidentify refrigerants
If an HFC-134a (or HFO-1234yf) air conditioning
system is mistakenly charged with another
refrigerant, serious problems such as compressor
seizure may occur. Therefore, confirm before
charging with refrigerant that the type of air
conditioning system is an HFC-134a (or
HFO-1234yf) system.
2.Do not release refrigerant into the air
Although HFC-134a (or HFO-1234yf) 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 conditioner system, always use a refrigerant
recovery unit made especially for HFC-134a (or
HFO-1234yf).
Compressor handling
Do not strike or unnecessarily turn the compressor
upside down. If the compressor is knocked over or
turned upside down during handling or installation,
rotate the armature plate 5 or 6 times by hand to
circulate the oil. Otherwise, oil in the cylinder
during compressor start-up will cause valve
damage and reduce durability.
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.
Safety glasses
Gloves
Do not release refrigerant into the air
Recovery unit
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