TM55-65 Servicemanual en

SERVICE
MANUAL
Valeo TM55 & TM65 Compressors
Copyright © 2014 Valeo Japan CO., LTD. | All Rights Reserved.

Oil fill-up plug for better
inner oil return
7 double-headed pistons architecture

ensuring smooth and quiet operations
Compact & robust design enabling

easy mounting configurations
Lip type shaft seal providing
ultimate reliability & performance
Light & Compact, Ultimate Reliability, Highest Performance

Foreword
This service manual has been elaborated to help The contents of the manual, including illustrations,
service personnel to provide efficient and correct drawings and specifications were the latest
service and maintenance on Valeo TM55 and available at the time of printing.
TM65 compressors for bus 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 proper 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 conditioning maintenance.
-1-
Contents
1- Product description........................................................................ 3
Compressor speed (rpm)................................................................... 7
Conversion factors.............................................................................. 7
2- Operation precautions................................................................. 15
3- Handling instructions................................................................... 16
Maintenance precautions.................................................................16
Work area...............................................................................................16
Refrigerant handling.............................................................................16
Compressor handling........................................................................17
Compressor removal.........................................................................17
Oil return operation..........................................................................18
Oil handling.......................................................................................18
Oil level at inclination conditions.....................................................19
Front Lifting.......................................................................................19
Lateral Inclination.............................................................................19
Oil contamination.............................................................................20
Oil check............................................................................................20
Replacement of components...........................................................21
Running-in operation........................................................................22
Compressor running-in..........................................................................22
Magnetic clutch running-in...................................................................22
Leak test............................................................................................23
Storing a repaired compressor.........................................................23
4- Troubleshooting........................................................................... 24
Compressor troubleshooting.................................................................24
Compressor troubleshooting tree.........................................................24
A/C cycle diagnosis by gauge pressure...............................................27
5- Tightening torques....................................................................... 29
6- Service procedures - Magnetic clutch......................................... 30
7- Service procedures - Shaft seal assembly.................................. 36
8- Service procedures - Cylinder heads........................................... 39
9- Service tools................................................................................. 43
10- Service parts.............................................................................. 53
-2-
1- Product description - Compressor
Compressor
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 Suction: 35 mm (1-3/8 in) Suction: 35 mm (1-3/8 in)

Internal Hose Diameter Discharge: 28 mm (1-1/8 in) Discharge: 35 mm (1-3/8 in)
WEIGHT 18.1kg / 39.9 lbs (w/o Clutch)
DIMENSIONS 341 - 194 - 294 (mm)
Length - Width - Height 13.4 - 7.64 - 9.33 (in)
MOUNTING Direct (side or base)
Valeo TM55 & TM65 Application limits

tc (oC ) (0.03 MPaG) (0.10 MPaG) (0.19 MPaG) (0.31 MPaG) (0.47 MPaG)
90
Saturated condensing temp
(2.65 MPaG)
80
70
60
(1.58 MPaG)
50
40
(0.76 MPaG)
30
20
(0.47 MPaG)
-30 -20 -10 0 10 20 30
te (oC )
tc : Condensing temperature (oC) Saturated evaporating temp
te : Evaporating gas temperature (oC)
-3-
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.
Name plate
Tip
As TM55 & TM65 compressors have the same
dimensions, the best way to differentiate them
quickly is by referring to the name plate.
COMP. TYPE TM-XX

PART NO. ZXXXXXXX X
SERIAL NO. X X X X X X X X X X
OIL ZXL 100PG 1500 cm3
HIGH SIDE 2.9MPaG
LEAK TEST LOW SIDE 1.5MPaG
REFRIG. HFC-134a
M A D E I N J A PA N
-4-
1- Product description - Magnetic clutch
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.
Specifications*
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)

*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.
Valeo TM55 & TM65 magnetic clutch

Compact and robust design
Housing mounted magnetic clutch.
Improved robustness to vibration
Bearing and pulley positionned to

reduce efficiently the moment of tilt
Single level or multi-level pulleys
-5-
1- Product description - Connectors
Connectors
1. Fully open the shut-off valve when operating the compressor
• Unscrew the cap.
• Loose the valve spindle seal 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 seal carefully and screw the cap.
1
4 2 1 Valve spindle seal
2 Cap
3 3 Spindle
4 Service port connector
5 Safety devices port
5
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.
1
2 Cap
3 3 Spindle
5 5 Safety devices port
3. Fully close the shut-off valve when removing the compressor

• Turn the spindle in the clockwise direction until it stops.
1
2 Cap
3 3 Spindle
5 Safety devices port
5
-6-
1- Product description - Performance
The performance data below were measured under the following conditions:
• Compressor speed: 1450 rpm
• Suction gas temperature: 20°C
Valeo TM-55 performance data (R134a)

Conditions Cooling Capacity Q and Power Consumption P
Evap temp
Cond. Pd -10 -5 0 5 10 12.5
(oC )
temp (oC ) (MPaG)
Ps (MPaG) 0.10 0.15 0.19 0.24 0.32 0.35
Q (kW) 14.73 19.68 23.88 29.30 37.23 40.31
40 0.91
P (kW) 5.31 5.96 6.39 6.77 7.21 7.36
Q (kW) 12.75 17.52 21.06 25.58 32.97 35.54
50 1.21
P (kW) 5.80 6.59 7.09 7.63 8.32 8.48
Q (kW) 10.53 14.42 17.60 21.39 28.16 30.65
60 1.58
P (kW) 6.28 7.21 7.84 8.52 9.38 9.63
Valeo TM-65 performance data (R134a)
Conditions Cooling Capacity Q and Power Consumption P
Evap temp
Cond. Pd -10 -5 0 5 10 12.5
(oC )
temp (oC ) (MPaG)
Ps (MPaG) 0.10 0.15 0.19 0.24 0.32 0.35
Q (kW) 17.29 22.96 28.21 33.92 42.18 45.71
40 0.91
P (kW) 6.30 7.02 7.53 8.10 8.68 8.90
Q (kW) 15.16 20.21 24.24 29.31 37.58 40.37
50 1.21
P (kW) 6.83 7.76 8.39 9.06 9.90 10.11
Q (kW) 12.66 17.30 20.80 25.28 32.10 34.56
60 1.58
P (kW) 7.35 8.43 9.17 9.95 11.02 11.35
Valeo TM55 & TM65 conversion factors

The performance data at different rotation speed can be approximated with the conversion factors
below.
3.0
2.5 P
Conversion factors
2.0
Q
1.5
1.0
0.5
0.0
0 1000 1450 2000 3000 4000
Compressor speed (rpm)
-7-
1- Product description - Dimensions
TM55 & TM65 compressors with magnetic clutch
354
253.4
221.8
142.4
190
∅ 220
∅ 186
165
∅
84
12-M12x1.75 Dp.26
111.8 140
Sight glass
CB104 CA104
500
(From field coil)
56.5
56.5
-8-
1-Product description - Dimensions
TM55 & TM65 compressors without magnetic clutch
15° 31.3 85.8 110
1.6
142.4
6-M6x1.0,Dp13
PCD ∅ 90
∅ 47.35
∅ 65
∅ 50
∅ 190
165
165
84
85
84
∅ 17.6
∅ 32
∅ 27
8-
12-M12x1.75,Dp26 15
162 (70) (70)
85.8 140
4- ∅ 27
296.6
194
Sight glass
28
56
56.5
56.5
28
56
-9-
1- Product description - Exploded view
28
6 27
26
25
30
22 29
21 24
3
23
20
7 19
37
36
5
16 17 13
4 35
2 34
16
1
11
9 31
32
18 33
15
12 14
13
10
9
8
1. Center bolt 20. Eye bolt

2. Armature assembly 21. O-Ring
3. Adjusting shim 22. Oil filler plug
4. Snap ring 23. Strainer
5. Pulley assembly 24. Gasket
6. Screw 25. Connector
7. Field coil 26. Bolt
8. Bolt 27. Gasket
9. Gasket 28. Plate
10. Front cylinder head 29. Plate
11. Shaft seal assembly 30. Bolt
12. Snap ring 31. Sight glass
13. O-Ring 32. O-ring
14. Gasket 33. Snap ring
15. Valve plate assembly 34. Valve plate assembly
16. Suction valve 35. Gasket
17. Pin 36. Gear pump
18. Bolt 37. Rear cylinder head
19. Cylinder shaft assembly
- 10 -
1- Product description - Swash plate system
Valeo TM55 & TM65 are 14-cylinder swash plate Swash plate system
type compressors. With this type of compressor,
The drive shaft, which is driven by the engine
the cylinders and pistons are arranged axially
through the magnetic clutch, is equipped with a
along the drive shaft.
swash plate.
The pistons operate within the cylinders and
The drive shaft is supported by two radial bearings
are driven by a swash plate to perform suction,
and two thrust bearings.
compression and discharge.
The swash plate is rotated by the drive shaft, and
moves the pistons back and forth.
Drive shaft Radial bearing Thrust bearings Swash plate Piston Radial bearing
Piston Drive System

Radial bearing
The pistons in the cylinders are mounted on the
swash plate through hemispherical shoes.
Each piston has a compression head at each end.
Swash plate rotation results in a reciprocating
piston movement horizontal to the drive shaft.
The cylinders, which are arranged at 51.4° intervals
around the drive shaft, are each divided into 2
Thrust bearing chambers, providing 7 front and 7 rear bores.
As each piston performs suction and compression
at either end, the compressor operates as a 14
Suction Suction cylinder compressor.
Compression Compression
Piston Shoe
- 11 -
1- Product description - Lubrication
The gear pump situated at the end of the drive shaft draws oil from the oil reservoir and lubricates the parts
of the compressor.
Oil flow
When the compressors start 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 shoes is lubricated by the splashing action of the oil flowing
through the thrust bearings. The compressor remains constantly lubricated thanks to the oil circulating
together with the refrigerant.
Valeo compressor innovative internal design ensures that almost no oil remains mixed with the refrigerant
that is flushed into the air conditioning system.
Refrigerant itself plays a lubricant role to prevent the compressor to be damaged in case of oil shortage.
Drive shaft Shaft seal Swash plate Radial bearing Gear pump
Radial bearing Reservoir Sight glass Thrust bearings Oil passage Oil passage
- 12 -
1- Product description
Compressor
1. The direction of rotation is clockwise as viewed
from the clutch side.
2. The standard compressor oil charge is specified
for bus air conditioners. The oil quantity may
differ depending on the type and use of
compressor. Please refer to the label on the
compressor.
Operation condition table 3. The compressor must be operated under the

Item Condition conditions shown in the operation condition
Surrounding table shown at left.
Under 120°C (248°F)
temperature
CAUTION!
Minimum: 600 r/min
Speed Maximum: 4500 r/min The A/C cycle components must be
Continuous: 4000 r/min designed so that the pressure in the cycle
does not exceed 2.65 MPaG {28 kgf/cm2,
Maximum: 2.65 MPaG
Pressure 385 psig}
{28kgf/cm², 385 psig}
4. Inclination limit at installation

15˚ 15˚ The compressor must be installed on the vehicle
within the range shown at left.
Front head forward leaning is prohibited.
5˚ Compressor mounting points

The compressor’s mounting points should be
tightened to the specified torque:
Specified torque: 45 ~ 50 N·m
{4.6 ~ 5.1 kgf·m, 33.2 ~ 36.9 lbf·ft}
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.
2. Vibration resistance
There must not be any resonance under 250
HZ.
- 13 -
1- Product description
Magnetic clutch
1. Voltage
DC 24 V
The terminal voltage of the magnetic clutch
must exceed 21 V.
DC 12 V
The terminal voltage of the magnetic clutch
must exceed 10.5 V.
2. Ratio of magnetic Clutch to drive pulley

1 mm
• When the compressor is driven from the pulley
drive of the vehicle, the magnetic clutch to
Magnetic clutch drive pulley ratio should avoid the range 1:
0.92~1.08 to limit vibration and resonance.
• Compressor speed must not exceed the
Idle pulley
specified speed.
Drive pulley
CAUTION!
Pulley ratio is the ratio of the magnetic clutch
diameter to the drive pulley diameter.
3. Pulley alignment tolerance is less than 1mm

(0.04 in).
4. Pulley groove: V-groove or V-ribbed.
5. The V-belt tension must be adjusted to the
tension specified by the belt maker.
- 14 -
2- Operation precautions
1. In the off season of air conditioner, operate
the compressor for a few minutes from time
to time.
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

while cleaning the vehicle.
- 15 -
3- Handling instructions
Maintenance precautions
Work area
Because the components of air conditioners are
especially 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 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 especially dangerous during the gas
leak inspection following installation)
WARNING!
Contact with flame and high temperatures
Safety glasses can generate toxic gases.
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 mistake 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.
- 16 -
Do not release refrigerant into 2. Do not release refrigerant into the air
the air Although HFC-134a is not subject to CFC regulations,
it can have effect on global warming and so should
FILL
AUTO
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.
Compressor handling
Recovery unit 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.18).
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.19).
When the compressor is inoperable

1. Recover the refrigerant from the system using
a refrigerant recovery unit if the shut-off valves
are 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.19).
- 17 -
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) or POE oil.
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.
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.
As long as it remains within the range of vision
through the sight glass, the oil quantity is sufficient
Oil level can be read through the sight glass of he
compressor (see on the left).
- 18 -
15˚ 15˚
Oil level at inclination
conditions
Compressor lateral inclination and front lifting at
the same time are allowed so consider this factor
during sight glass inspection (distorted indication).
5˚
Oil level inspection should be conducted at low
compressor speed or compressor stopped. Sight
glass cannot be used at high compressor speed
because oil surface is not visible and a mixture of
refrigerant and oil is formed.
A flashlight can be helpful to expose oil surface:

light up one of the sight glasses to read oil level at
the opposite one.
CAUTION!
Be careful of rotating parts and high
temperature parts.
5˚
Front Lifting
In most of bus rear application, the front end of
the compressor is lifted to fit the inclination of the
engine.
1. Oil level at sight glass: oil level is distorted.
2. Oil amount: quantity appears lower than
recommended but the level is actually correct,
you do not need to add more oil.
Lateral Inclination
15˚ 1. Oil level at sight glass: one sight glass will look
completely covered with oil while the other
will look inferior to recommendation or even
empty.
2. Oil amount: in this case, some of the oil is
below oil passage level, therefore you should
consider adding some oil to fill in the dead
volume that appears in the illustration on the
left.
Oil passage
Oil amount below oil

passage level
- 19 -
Oil contamination
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor is run for a
long time, 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.
Oil check
The compressor oil must be checked as follows
when being charged into a used system.
1. Perform the oil return operation (p.18).
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. Fill the compressor with the specified amount
of oil (p.20)
- 20 -
unit: cm3 & cc
CAUTION!
Amount The specified oil quantity differs, depending
Specified Amount Charging to remove
on the type of air conditioner system. A
charge recovered amount from new
label describing the specified quantity is
compressor
attached to the compressor. Additionally, all
1500 - of the oil cannot be removed when draining
1000 or Same as
(amount the compressor as some remains as an oil
more recovered
1500 recovered) film on the inside of the compressor and
Under the system components. Therefore, refer
1000 500
1000 to the table at left when recharging the
compressor with oil. Excess oil adversely
unit: cu in affects the cooling capacity and the
Amount compressor.
Specified Amount Charging to remove
charge recovered amount from new 6. Install the oil filler plug and tighten it to the
compressor specified torque.
61 or Same as 61 - (amount Specified torque: 15 - 18 N·m
91.5 more recovered recovered) {1.5 - 1.8 kgf·m, 11 - 13 lbf·ft]
Under 61 61 30.5
CAUTION!
The oil filler plug O-ring must be replaced
with a new one.
Replacement of components
When replacing the component parts of the
system, supply the following amount of oil to the
compressor.
Component mounted Amount of oil

Evaporator 300 cm3 (18.3 cu in)
Condenser 200 cm3 (12.2 cu in)
Receiver drier 100 cm3 (6.1 cu in)
Pipe or hose 100 cm3 (6.1 cu in)
After installing these component parts, check the

compressor oil. Refer to page 18.
- 21 -
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 specific
amount of oil.
2. Install the compressor on the test bench.
3. Install the high pressure connector and the low
pressure connector to the ports and tighten the
bolts to the specified torque.
Specified torque: 25 - 32 N·m
{2.5 - 3.3 kgf·m, 18 - 24 lbf·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 700 rpm.
Operate the A/C switch through the ON/OFF
cycle at least 50 times (“ON” for 10 seconds
and “OFF” for 10 seconds).
- 22 -
Leak test
The compressor must be checked for refrigerant
leaks after it is repaired. The procedure is as
follows.
1. Fit the connectors to the suction and discharge
connections, and tighten it to the specified
torque.
{2.5 - 3.3 kgf·m, 18 - 24 lbf·ft}
2. Fill the compressor with refrigerant through the
suction side, raising the refrigerant pressure to
at least 0.39 MPaG {5 kgf/cm2, 56.3 psig}.
3. Check the compressor for leaks using a leak
detector.
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 30 ~ 100
kPa {0.3 - 1.0 kgf/cm2, 4.4 - 14.5 psi}.
- 23 -
4- Troubleshooting
Compressor troubleshooting
When a trouble occurs during the compressor operation, it is often difficult to pinpoint exactly 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 in case it ever happens, we hope this troubleshooting can help you solve
the issue efficiently.
Below are listed most of the troubles 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 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 recommand 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
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
- 24 -
4- Troubleshooting
1. Insufficient cooling capacity
Trouble Symptom Possible cause Measure
Compressor is Magnetic clutch slips when Compressor internal part
Replace the compressor
not running turning on the A/C switch damage
(No cool blow Fix the refrigerant leakage
coming out) Low pressure cut switch
Refrigerant shortage then fill with refrigerant until
operate (see p.26 - 27)
having the right amount
The magnetic clutch slips or Lead wire short circuit or

Replace the lead wire if it is
does not engage when the wiring connector not seated
defective
compressor runs properly
Repair or replace the
Magnetic clutch damage
magnetic clutch
A Magnetic clutch air gap too Adjust air gap or replace
wide magnetic clutch
Low magnetic clutch voltage Charge battery
The magnetic clutch engages
Replace the compressor if it
but the armature does not Belt slipping
is locked
rotate
Compressor internal part

Replace the compressor or
Belt run off the pulley damage or magnetic clutch
the magnetic clutch
damage
Center bolt is loose / Center Bolt drop off/ Armature drop
Replace magnetic clutch
bolt is missing off
Compressor is Compressor is running

Poor compression Replace the compressor
running normally
(No cool blow No difference of temperature Fix the refrigerant leakage
coming out) between discharge side and Refrigerant shortage then fill with refrigerant until
suction side (see p.26 - 27) having the right amount
The magnetic clutch slips or

Magnetic clutch friction Charge the battery or replace
does not engage when the
B surface slipping the magnetic clutch
compressor is running
Loose connection of the Replace the magnetic
magnetic clutch electrical clutch after making sure it is
circuit defective
Belt slipping Magnetic clutch belt slipping Belt tension readjustment
The magnetic clutch does Replace the sensor after
Defective sensor
not engage making sure it is defective
Compressor Reduce the refrigerant

Both discharge and suction
runs Excess of refrigerant charge until reaching the
pressures are high
intermittently right amount
(Cool blow
comes out only Replace the condenser after
Condenser fan failure
from time to making sure it is defective
C
time) The magnetic clutch slips or Loose connection of the Replace the magnetic
does not engage when the magnetic clutch electrical clutch after making sure it is
compressor is running circuit defective
The magnetic clutch does Replace the sensor after
Defective sensor
not engage making sure it is defective
- 25 -
4- Troubleshooting
2. Abnormal noise
Abnormal Abnormal vibration after Compressor installation bolt Increase tightening torque of
noise from the turning on the A/C switch is loose the loose bolts
compressor
Wide gap at the attaching
Improve the compressor
A portion between the
attaching portion
compressor and the bracket
Abnormal noise from the Compressor body internal
Replace the compressor
compressor body component damage
Abnormal The magnetic clutch has a

Magnetic clutch damage Replace the magnetic clutch
noise from the backlash and slips
magnetic clutch Strange noise when the Adjust air gap or replace
Air gap too wide
B magnetic clutch engages magnetic clutch
Armature slips / does
Magnetic clutch friction Charge battery or replace
not engage when the
surface slipping magnetic clutch
compressor is running
Abnormal Armature does not rotate Replace the compressor if

C noise from the when magnetic clutch Belt slipping locked. Readjust the belt
magnetic clutch engages tension if the belt is loose
3. Smoke
Magnetic The magnetic clutch slips /
Magnetic clutch air gap too Adjust air gap or replace
clutch friction does not engage when the
wide magnetic clutch
surface slipping compressor is running
A
Low magnetic clutch voltage Charge battery
Magnetic clutch friction Clean friction surface or
surface is greasy replace magnetic clutch
Magnetic The magnetic clutch slips /

Adjust the compressor
clutch belt does not engage when the Belt alignment is not correct
installation position
slipping compressor is running
B Magnetic clutch belt is
Clean or replace the belt
greasy
Magnetic clutch belt tension
Adjust belt tension
is loose
Smoke from
The magnetic clutch does
C the magnetic not engage
Coil open or shorted Replace the magnetic clutch
clutch
Refrigerant leaking, Fix the refrigerant leakage

Smoke from Refrigerant / oil is billowing
D the compressor out
uncoupled piping or piping then fill with refrigerant until
burst having the right amount
- 26 -
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 mesuring:
1. Ambient temperature: 30 - 35 °C
2. Engine speed: 1.500 rpm
3. A/C switch: ON
4. Blower speed: high
5. 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
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/cm²)
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 Outlet side of TXV is Replace part
from TXV temperature not cooling.
sensing tube. (Low side of gauge
(TXV operates to close indicates vacuum)
the valve opening)
Temperature sensing Evaporator becomes Adjust or replace the
device at outlet air is 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 Excess of refrigerant Connect gauge Recover refrigerant,
suction pressures are manifold to cycle then refill with the
high right amount of
refrigerant
Condenser cooling Condenser becomes Clean up, hand repair
malfunction muddy and fins are of fin and replacement
clogged and collapsed.
Defect of cooling fan
rotation.
Malfunction of fan
motor for condenser.
Misaligned TXV or Defective refrigerant Adjustment or
thermal sensing tube flow control, the replacement
of TXV is not fit on thermal sensing tube
regularly. is not closely in contact
(Excess opening of TXV) with the evaporator
pipe
Air mixed in Just after compressor Evacuate air from cycle,
refrigeration cycle stops, discharge the charge with the
pressure will come adequate amount of
down immediately to refrigerant.
0.19 - 0.29 MPaG (3 - 4
kgf/cm²)
Discharge pressure Refrigerant cycle is Appreciable Clean up inside the
is high and suction clogged between temperature difference cycle or replace the
pressure is low compressor and at the clogged location part
condenser
Discharge pressure Defect of the Discharge and suction Replace the compressor
is low and suction compressor valve or pressures balance
pressure is high gasket immediately after the
compressor stops.
(Defective compression
of compressor)
- 28 -
5- Tightening torques
2
5
6
1
3
Unit: N·m {kgf·m, lbf·ft}
Part Thread size Tightening torque

1. Center bolt M10 x 1.25 25 - 30 {2.5 - 3.1, 18 - 22}
2. Field coil screw M6 x 1.0 4.2 - 7.2 {0.4 - 0.7, 3.1 - 5.3}
3. Bolt M10 x 1.5 25 - 32 {2.5 - 3.3, 18 - 24}
4. Oil filler plug M10 x 1.5 15 - 18 {1.5 - 1.8, 11 - 13}
5. Connector bolt M10 x 1.5 25 - 32 {2.5 - 3.3, 18 - 24}
- 29 -
6- Service procedures - Magnetic clutch
Magnetic clutch
Removal
1. Check your armature type (see at left):
• 3-hole type (1)
• 2-way stopper type (2)
3-hole type (1) 2-way stopper type (2)
2. Remove the armature.

Armature
holder
CAUTION!
The armature removal process differs
according to the armature type
• If it is a 3-hole type armature (1)

a. Remove the center bolt using an armature
holder to prevent armature assembly rotation.
b. Remove the armature assembly using an

Armature puller armature puller assembly. Remove the shims
assembly from the compressor driveshaft or armature
assembly.
• If it is a 2-way stopper type armature (2)

a. Remove the center bolt using a spanner to
prevent armature assembly rotation.
Spanner
- 30 -
b. Remove the armature assembly using an
Armature puller armature puller. Remove the shims from the
compressor driveshaft or armature assembly.
3. Remove the snap ring (Z0010244) using

external snap ring pliers.
External snap
ring pliers
Snap ring
4. Position the center pulley puller at the end of

the driveshaft.
Center pulley 5. Attach a suitable pulley puller to the pulley.
puller Hook the puller claws to the edge of the pulley
Pulley puller as shown.
6. Tighten the center pulley puller bolt to remove
the pulley.
7. Remove the six field coil/compressor screws.

Then remove the field coil.
WARNING!
Removing the pulley will systematically
damage the pulley bearing.
CAUTION!
Do not clip the puller claws into the pulley
groove to prevent pulley groove damage.
CAUTION!
Do not hold the field coil by the harness.
- 31 -
Magnetic clutch
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 pulley and
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.
Installation
1. Install the field coil on the compressor (with
the harness on top) and tighten the mounting
screws to the specified torque.
Screws
Specified torque: 4.2 - 7.2 N·m
{0.4 - 0.7 kgf·m, 3.1 - 5.3 lbf·ft}
2. Carefully place the wire harness/strain relief.
Field coil
Press • If you are using a press

Pulley assembly 3. Install the pulley assembly using the pulley
Pulley
installer installer and the press.
CAUTION!
Use only a press to install the pulley
assembly. Do not use a hammer. The use
of a hammer may result in damage or
deformation.
- 32 -
3-hole 4. Install the armature assembly on the driveshaft
Armature
armature (1)
holder together with the original shim(s) and press it
down.
5. Install the armature bolt and tighten it to the
Adjusting specified torque using an armature holder
shims (for 3-hole armature) or a spanner (for 2-way
stopper armature) to prevent armature
assembly rotation.
{2.5 - 3.1 kgf·m, 18 - 22 lbf·ft}
2-way stopper
armature (2) Spanner
Adjusting
shims
6. Check that the clutch clearance is as specified.

If necessary adjust the clearance using shim(s).
Adjusting shims are available in the following
thicknesses:
Gap adjustment
0.3 - 0.7 mm
Shim Part No. Thickness
Z0010245 0.2 mm {0.008 in}
Z0010246 0.3 mm {0.012 in}
Thickness
gauge
Specified clearance: 0.3 - 0.7 mm
{0.012 - 0.028 in}
8. Run in the clutch as described on page 21.
- 33 -
• If you are not using a press
3. Install the pulley using a pulley installer
assembly and a spanner.
CAUTION!
If the bolt of the pulley installer assembly
is not screwed into the driveshaft, it may
result in damage.
4. Once the pulley is fixed, loose the collar and

remove the pulley installer assembly.
5. Install the snap ring (beveled edge up) using

external snap ring pliers.
Snap ring
External snap
ring pliers
- 34 -
3-hole 2-way stopper 6. Install the armature assembly on the driveshaft
armature armature together with the original shim(s).
Adjusting
shims
3-hole armature 2-way stopper armature 7. Install the armature assembly using an
armature installer assembly.
Armature
installer
assembly
3-hole armature 2-way stopper armature 8. Install the armature bolt and tighten to the
specified torque using an armature holder
Armature Spanner or a spanner to prevent armature assembly
holder
rotation.
{2.5 - 3.1 kgf·m, 18 - 22 lbf·ft}
9. Check that the clutch clearance is as specified.

If necessary adjust the clearance using shim(s).
Adjusting shims are available in the following
thicknesses:
Gap adjustment
0.3 - 0.7 mm
Shim Part No. Thickness
Z0010245 0.2 mm {0.008 in}
Z0010246 0.3 mm {0.012 in}
Thickness Specified clearance: 0.3 - 0.7 mm

gauge
{0.012 - 0.028 in}
10. Run in the clutch as described on page 21.
- 35 -
7- Service procedures - Shaft seal assembly
Removal
Bolt
1. Remove the magnetic clutch assembly as
described on page 29.
2. Remove the 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 seven bolts securing the head
using an hexagon (14 mm) wrench.
5. Alternately tap the two projections on the front

head using a remover and a mallet to remove
the front cylinder head.
Tap lightly
Remover
Front cylinder head
6. Remove the snap ring using the internal snap

ring pliers.
Snap ring
Internal snap
ring pliers
Press uniformly Shaft seal 7. Remove the shaft seal assembly using a
from above remover.
Front cylinder head Remover
- 36 -
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.
Press using a press Installation

1. Clean the portion of the front cylinder head
Remover where the shaft seal is to be assembled.
2. Assemble the shaft seal on the remover.
Shaft seal 3. Coat the shaft seal well with compressor oil
and install the shaft seal in the front cylinder
head with the shaft seal remover.
4. Install the snap ring using the internal snap
ring pliers.
Front cylinder head
Front cylinder head

5. Position the guide on the shaft
6. Coat the new O-ring with clean compressor oil
O-ring
and install it in the front cylinder head
Guide 7. Install the front cylinder head
CAUTION!
Align the pins and tap the head lightly and
evenly with a plastic hammer.
8. Remove the guide

9. Install the seven bolts from the front cylinder
head side and tighten them to the specified
torque:
{2.5 - 3.3 kgf·m, 18 - 24 lbf·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.
- 37 -
Oil filler plug
of clean compressor oil through the oil filler.
O-ring 12. Install the oil filler plug with a new O-ring, and
tighten it to the specified torque:
{1.5 - 1.8 kgf·m, 11 - 13 lbf·ft}
13. Install the strainer in the suction port.
14. Fit the blanking plates/connectors to the
suction and discharge connections, and tighten
them to the specified torque:
{2.5 - 3.3 kgf·m, 18 - 24 lbf·ft}
15. Install the magnetic clutch as described on
page 31.
16. Run in the compressor as described on page
21.
17. Perform the leak test as described on page 22.
- 38 -
8- Service procedures - Cylinder heads
Cylinder heads (Front & Rear)
Disassembly
Bolt
1. Remove the magnetic clutch assembly as
described on page 29.
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 seven bolts securing the heads.
5. Alternately tap the two projections on the front

head using the remover and mallet to remove
the front cylinder head.
Tap lightly
Remover
Front cylinder head
Suction valve
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.
Gasket
8. Remove all gasket material from the front
cylinder head and the front valve plate.
Valve plate assembly

O-ring
- 39 -
9. Alternately tap the two projections on the rear
head using the remover and mallet to remove
the rear cylinder head.
Tap lightly
Remover
Rear cylinder head
Gasket 10. Remove the rear valve plate assembly and

then the suction valve (in that order).
Suction valve
11. Remove and discard the O-ring from the rear
cylinder head.
12. Remove all gasket material from the rear
O-ring cylinder head and the rear valve plate.
Valve plate
assembly
13. Remove the gear pump from the rear cylinder

head or the end of the driveshaft.
Gear pump Rear cylinder head
Inspection
Check the front and rear valve plates for scratched,
bent or damaged parts.
Inspect both cylinder heads and both valves 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.
Valve plate Cylinder head
Check that there are no clogged passages in the
valve plates.
- 40 -
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 pins.
CAUTION!
Ensure each valve matches 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.
Gear pump
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.

Rear cylinder head 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
Gear pump
head.
O-ring
Gasket
Valve plate
assembly
Suction valve
- 41 -
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
O-ring
the spring pins.
Gasket CAUTION!
Ensure each valve matches each cylinder
Valve plate valve escape groove.
assembly
3. Install the front valve plate on the front suction
Suction valve valve.
4. Coat the new gasket with clean compressor oil
and install it on the front valve plate.
Guide Pins
5. Position the guide on the shaft.
and install it on the front cylinder head.
7. Install the front cylinder head.
CAUTION!
Align the spring pins and tap the head
lightly and evenly with a plastic hammer.
8. Remove the guide.

9. Install the seven bolts from the front cylinder
head side and tighten them to the specified
torque.
Specified torque: 25 ~ 32 N·m
{2.5 - 3.3 kgf·m, 18 - 24 lbf·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.
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.
{1.5 - 1.8 kgf·m, 11 - 13 lbf·ft}
Oil filler plug
13. Install the strainer in the suction port.
O-ring
14. Fit blanking plates/connectors to the suction
and discharge connections, and tighten it to
the specified torque.
{2.5 - 3.3 kgf·m, 18 - 24 lbf·ft}
15. Install the magnetic clutch (see p.31).
16. Run in the compressor (see p.21).
17. Perform the leak test (see p.22).
- 42 -
9- Service tools
In addition to standard tools, numerous special tools are necessary to service the Valeo TM55 & TM65
compressors. The use of these special tools enables prompt and correct compressor service.
The drawings and the specifications of the service tools listed below are enclosed in the following pages.
Service tools
Ref. Drawing
Item Name Picture Application
page page
29,32,
1 Armature holder To fix armature 43
34
Armature installer
2 34 To install armature 43-44
assembly
Center pulley
3 30 To remove pulley 45
puller
4 Pulley installer 31 To install pulley 45
Pulley installer
5 33 To install pulley 46-47
assembly
Cylinder head 35, 38, To remove cylinder head and

6 48
remover 39 cylinder block
7 Guide 36, 41 To install shaft seal 48
Shaft seal remover To remove and insert the

8 35, 36 49
/ installer shaft seal
9 Armature puller 30 To remove armature 49
Armature puller
10 29 To remove armature 50-51
assembly
- 43 -
9- Service tools
1
2
Unless otherwise specified, 3rd Angle Proj. Surface Treatment Br

the edges to be slight chamfering. Heat Treatment
& Hardness
- -HQF - HTL
HRC40 to 45
Should remove burrs and fluff. Material 1 SS41 2 SS41 3 S45C
Part Name
Armature Holder
1 Bolt
2 Collar
1 2
3rd Angle Proj. Material

Surface Treatment
Heat Treatment
& Hardness
Material Assy
Part Name
Armature Installer Assy

- 44 -
9- Service tools
Armature Installer Assy 1
M10x1.25 M14x2.0
( 10.4 )
Ø 10
C1
Ø6
C1
°
45 9 -0.2
6 24 42 80 12
Unless otherwise specified,

3rd Angle Proj. Surface Treatment Br
the edges to be slight chamfering. Heat Treatment HQ-HQf
Should remove burrs and fluff. & Hardness HRC40 to 45
Material S45C
Part Name
Bolt
Armature Installer Assy 2
M14 x2.0
Ø 22
Ø 15
( 27.70 )
40 40 24 -0.35

Material S45C
Part Name
Collar
- 45 -
9- Service tools
Section view A-A
Unless otherwise specified, 3rd Angle Proj. Surface Treatment

& Hardness
- - -HQ - HTL
HRC40 to 45
Should remove burrs and fluff. Material S45C
Part Name
Center Pulley Puller
Section view A-A

& Hardness
HQ - HTL
HRC58
Should remove burrs and fluff. Material SK105 (JIS)
Part Name
Pulley Installer
- 46 -
9- Service tools
1 Bolt
2 Spacer
3 Collar
1 2 3
3rd Angle Proj. Material

Surface Treatment
Heat Treatment
& Hardness
Material Assy
Part Name
Pulley Installer Assy

Pulley Installer Assy 1
M10x1.25 M16x2.0 ( 13.9 )

Ø 12
Ø6
C2
C1
4 5
12 -0.25
6 24 15 100 15

Material S45C
Part Name
Bolt
- 47 -
9- Service tools
40
A 5 10 1
C0
±0.2
.5
-0.1
+0.2
-0.1
Ø 18
Ø 70
Ø 28.5
Ø 82.6
Ø 51
Ø 58
C5
C2
C0
A
.5
25
Section view A-A

the edges to be slight chamfering. Heat Treatment HQ-HTL
Should remove burrs and fluff. & Hardness HRC58
Material SK3
Part Name
Spacer
M16x2.0
( 27.7 )
-0.3
Ø 28
20 15 24 -0.35

Material S45C
Part Name
Collar
- 48 -
9- Service tools

& Hardness
Should remove burrs and fluff. Material SK85 (JIS)
Part Name
Remover (for cyl. head)

& Hardness
Should remove burrs and fluff. Material SUS304
Part Name
Shaft Seal Guide
- 49 -
9- Service tools
Section view A-A

& Hardness
- - -HQ - HTL
HRC40 to 45
Part Name
Remover
( 16.2 )
M12x1.75
R2
Ø7
R1
C1
5
14 -0.25
29 ±0.5 60 20

Material S45C
Part Name
Armature Puller
- 50 -
9- Service tools
1 Plate
2 Pole
3 Bolt
1
3
3rd Angle Proj. Surface Treatment

Heat Treatment
& Hardness
Material
Part Name
Armature Puller Assy

Armature puller assy 1
6-6 (15)
0°± 2-C1.0
0.1
°
12-C1.0
PC
D5
0±
0.1
2-C1.0
Ø70
6-M12X1.75
M16X2.0

& Hardness
Part Name
Plate
- 51 -
9- Service tools
(152)
(35) (42) (57) (18) (12)

Ø10.5
Ø16
Ø10
(13.9)
Ø7
R2 R1.5 R 30°
C1.0 M16X2.0 (2)

& Hardness
- -HQ - HQf
HRC40 to 45
Part Name
Pole
(0.5)
45°
R1.5
(0.5)
Ø9.5
Ø5
(96)
A section detailed view

(10/1)
(9) (30) (7) (30) (20) (12)
(7) A
Ø10
Ø9.5
Ø10
(13.9)
C1.0
M6X1.0 M12X1.75 30°

& Hardness
Part Name
Bolt
- 52 -
10- Service parts
1. Compressor body service kits, sets and parts
Item* Part name Reference Quantity

OVERHAUL KIT
Z0014427 -
(O-RING SET + GASKET SET + SHAFT SEAL)
O-RING SET Z0014430 -

12 O-ring body (front & rear head) Z0004833 n=2
20 O-ring drain 569300-4000 n=1
GASKET SET Z0014431 -

13 Gasket front head Z0004779 n=1
31 Gasket rear head Z0004780 n=1
9 Gasket (bolt) 9 per set 569310-6200 n=9
SHAFT SEAL (for service) - -

11 Shaft seal Z0007461 n=1
OTHER COMPRESSOR PARTS - -

14 Valve plate assy (front) Z0004775 n=1
30 Valve plate assy (rear) Z0004777 n=1
15 Suction valve Z0004774 n=1
*See Product description - Exploded view (p.10)
2. Connector assy (Z0011222) service parts
Item* Part name Reference Quantity Remarks

24 Connector (body) Z0011223 n=1 Dis./Suc.
23 Gasket Z0011226 n=1 For conn.
26 Gasket Z0011227 n=1 For piping
25 Bolt Z0011228 n=2 For conn.
*See Product description - Exploded view (p.10)
3. Oil
Item Part name Reference Quantity

- ZXL 100PG (250 cc) 569900-0600 250 cc
- 53 -
VALEO COMPRESSORS - TM55 & TM65 for HFC-134a use
SERVICE MANUAL
Version: WW5565-14004.02EN
Published by: VALEO JAPAN CO, LTD.
Printed in Japan
Copyright 2014, VALEO JAPAN CO, LTD.
For any inquiry regarding the present service manual,

contact us at [email protected]
Valeo TM55 & TM65 Compressors for Bus Air-Conditioning.
Valeo TM55 & TM65 Benefits

High reliability
Integration flexibility
Great cooling capacity
Enhanced performance
Lower fuel consumption
Compact & robust design
Improved field serviceability
Reduced noise and vibrations
Staggering value through innovation
Asia China Europe, Middle East & Africa Americas

39 Sendai, Kumagaya-shi No.2677 Shiji Avenue, Eco. & Tec. Dvt 8, rue Louis Lormand ZA de l’Agiot 2520 Esters Blvd #100
Saitama-ken 360-0193 Japan Zone 130031 Changchun, Jilin PRC 78321 La Verriere, France Dallas, TX 75261 United States
Phone: +81 (0) 48 539 3800 Phone: +86 (0) 431 8499 2025 Phone: +33 (0) 1 3013 5027 Phone: +1 972 456 1077
Fax: +81 (0) 48 539 3843 Fax: +86 (0) 431 8499 2004 Fax: +33 (0) 1 3461 5898 Fax: +1 972 456 1090
Email: [email protected] Email: [email protected] Email: [email protected] Email: [email protected]
Copyright © 2014 Valeo Japan CO., LTD. | All Rights Reserved.

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7 double-headed pistons architecture

Compact & robust design enabling

Light & Compact, Ultimate Reliability, Highest Performance

VALEO JAPAN CO., LTD.

WARNING! Maintenance must be properly done to avoid serious injury risks.

CAUTION! Improper maintenance can result in injury or proper damage.

Advice Procedures necessary to ensure the best air conditioner maintenance.

Note Information to optimize the air conditioning maintenance.

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

CONNECTIONS Suction: 35 mm (1-3/8 in) Suction: 35 mm (1-3/8 in)

Valeo TM55 & TM65 Application limits

COMP. TYPE TM-XX

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)

Valeo TM55 & TM65 magnetic clutch

Bearing and pulley positionned to

2. Open the service port connector when using a gauge manifold

3. Fully close the shut-off valve when removing the compressor

Valeo TM-55 performance data (R134a)

Valeo TM55 & TM65 conversion factors

15° 31.3 85.8 110

1. Center bolt 20. Eye bolt

Piston Drive System

Operation condition table 3. The compressor must be operated under the

4. Inclination limit at installation

5˚ Compressor mounting points

2. Ratio of magnetic Clutch to drive pulley

3. Pulley alignment tolerance is less than 1mm

4. Keep the compressor clear of water projection

• Keep open flame and inflammables away from

1. Do not mistake refrigerants

When the compressor is inoperable

Oil quantity inspection

A flashlight can be helpful to expose oil surface:

Oil amount below oil

Component mounted Amount of oil

After installing these component parts, check the

Magnetic clutch running-in

Storing a repaired compressor

Most of the malfunction symptoms can be classified in the following categories:

Compressor troubleshooting tree

1. Insufficient cooling capacity A. Compressor is not running

C. Compressor runs intermittently

2. Abnormal noise A. Abnormal noise from compressor

B. Abnormal noise from magnetic clutch

C. Belt slipping noise