Valeo TM08 User manual

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Foreword
This service manual has been elaborated to help ser-
vice personnel to provide efficient and correct service
and maintenance on the TM08, TM13, TM15 & TM16
model compressors (for HFC-134a) for automotive 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.
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

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Contents
1-Product description................................................................................... 3
2-Operation precautions.............................................................................. 18
3-Handling instructions................................................................................ 19
Maintenance precautions............................................................................. 19
Work area............................................................................................... 19
Refrigerant handling.................................................................................. 19
Compressor handling.................................................................................. 20
Compressor removal................................................................................... 20
Oil return operation.................................................................................... 21
Oil handling............................................................................................... 21
Oil contamination....................................................................................... 22
Oil check.................................................................................................... 22
Replacement of components......................................................................... 23
Running-in operation................................................................................... 24
Compressor runnning-in............................................................................... 24
Magnetic clutch running-in........................................................................... 24
Leak test.................................................................................................... 25
Storing a repaired compressor ....................................................................... 25
Refrigerant charging................................................................................... 26
Installation position..................................................................................... 27
Installation precautions................................................................................ 27
Piping precautions....................................................................................... 28
4-Troubleshooting ........................................................................................ 29
Compressor troubleshooting ........................................................................ 29
Compressor troubleshooting tree .................................................................. 29
A/C cycle diagnosis by gauge pressure........................................................... 33
5-Tightening torques.................................................................................... 35
6-Service procedures - Magnetic clutch..................................................... 36
7-Services procedures - Shaft seal assembly.............................................. 40
8-Services procedures - Cylinder heads...................................................... 43
9-Service tools.............................................................................................. 47
Magnetic clutch service tools........................................................................ 47
Compressor tools....................................................................................... 48
Test and inspection tools ............................................................................. 48

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1-Product description - Magnetic clutch
Magnetic clutch
VALEO TM08, TM13, TM15 & TM16 are available either as a compressor and magnetic clutch assembly or as a
compressor body that customers can fit with compatible magnetic clutches. The magnetic clutch design Valeo
has been promoting for more than 20 years is now gradually adopted by other 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 TM08, TM13, TM15 & TM16 compressor qualities.
*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.
TYPE Electromagnetic single-plate dry clutch
RATED VOLTAGE 12 VDC & 24 VDC
POWER CONSUMPTION 49 W maximum
STATIC TORQUE 49 N·m {36 lb·ft}
DIRECTION OF ROTATION Clockwise & Counter clockwise (depending on clutch)
WEIGHT Approx 2.2 kg {4.9 lbs}
V-BELT TYPE V-groove (A or B) or V-ribbed (PK)
Specifications TM08, TM13, TM15 & TM16*

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1-Product description - Name Plate
Name plate
To ensure that the compressor operates smoothly,
respect carefully the indications written on the
name plate.
Tip
As TM13, TM15 & TM16 compressors have al-
most the same dimensions, the best way to
differentiate them quickly is by referring to the
name plate.
Name plate
COMP. TYPE TM-XX
PART NO. ZXXXXXXX X
SERIAL NO. XXXXXXXXXX
OIL ZXL 100PG 1500 cm3
LEAK. TEST HIGH SIDE 2.9MPaG
LOW SIDE 1.5MPaG
REF. HFC-134a MADE IN JAPAN
TMXX
XXXXXXX X
XXXXXXXXXX
ZXL 100PG XXX cm3
HFC-134a

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1-Product description - Dimensions TM08
135Ø
16
36.6 ±0.6
()183.3
61.6 67 ±0.1
89 ±0.1
11 ±0.1
120Ø
7/8-14UNF
SUCTION
3/4-16UNF
DISCHARGE
14°
14°
5.5
5
80
139.6( )
104 ±0.3
104 ±0.3
10.3 +0.4 Ø8-

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1-Product description - Dimensions TM13
135Ø
69.2
16
44.2 ±0.6
73.3 ±0.1
120Ø
12.4 ±0.1
98 ±0.1
208( )
7/8-14UNF 3/4-16UNF
DISCHARGE
SUCTION
21.5 28.5
80
142
104 ±0.3
104 ±0.3
10.3 +0.4 Ø8-
SD

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1-Product description - Dimensions TM15
135Ø
16
39.6 ±0.6
64.6 83.3 +0.2
14.35 +0.05
-0.15
112 ±0.1
215.8( )
120Ø
7/8-14UNF
SUCTION
3/4-16UNF
DISCHARGE
80
142
104 ±0.3
104 ±0.3
10.3 +0.4 Ø8-
21.5 28.5
D
S

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1-Product description - Dimensions TM16
112 ±0.1
135Ø
16
39.6 ±0.6
64.6
+0.05
-0.15
14.35
83.3
( )222.8
120Ø
+0.2
D
S
7/8-14UNF
SUCTION
3/4-16UNF
DISCHARGE
21.5 28.5
80
142
104 ±0.3
104 ±0.3
10.3 +0.4 Ø8-

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1-Product description - Exploded view
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
20
21
22
23
24
25
26
27
19
1. Center bolt
2. Armature assembly
3. Adjusting shim
4. Snap ring
5. Pulley assembly
6. Screw
7. Field coil
8. Bolt
9. Gasket
10. Snap ring
11. Shaft seal assembly
12. Front cylinder head
13. O-ring
14. Gasket
15. Valve plate assy
16. Sunction valve
17. Pin
18. Cylinder shaft assembly
19. Oil filler plug
20. Sunction valve
21. Valve plate assy
22. Gasket
23. O-ring
24. Rear Cylinder Head
25. O-ring
26. Relief Valve
27. Oil drain plug

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1-Product description - Performance TM08
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 TM08 performance data table (R134a)
TM08
Nc (r/min) 1200 1800 2400 3000
Vol. Eff. (%) 60.0 58.8 58.7 59.1
Capacity (kW) 1.57 2.31 3.08 3.87
Power (kW) 0.82 1.27 1.75 2.30
COP 1.93 1.82 1.76 1.69
Valeo TM08 performance data graph (R134a)
Compressor Speed (rpm)
Volumetric Efficiency (%)
Cooling Capacity (kW) / Power (kW) / COP

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1-Product description - Performance TM13
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 TM13 performance data table (R134a)
TM13
Nc (r/min) 800 1200 1800 2400 3000
Vol. Eff. (%) 58.3 63.0 65.7 63.7 61.1
Capacity (kW) 1.64 2.64 4.13 5.35 6.41
Power (kW) 0.92 1.41 2.22 3.04 3.93
COP 1.78 1.87 1.86 1.76 1.63
Compressor Speed (rpm)
Volumetric Efficiency (%)
Cooling Capacity (kW) / Power (kW) / COP
Valeo TM13 performance data graph (R134a)

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1-Product description - Performance TM15
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 TM15 performance data table (R134a)
TM15
Nc (r/min) 800 1200 1800 2400 3000
Vol. Eff. (%) 57.5 63.3 66.2 64.1 61.4
Capacity (kW) 1.81 2.98 4.65 6.03 7.24
Power (kW) 1.04 1.57 2.50 3.45 4.42
COP 1.73 1.90 1.86 1.75 1.64
Compressor Speed (rpm)
Volumetric Efficiency (%)
Cooling Capacity (kW) / Power (kW) / COP
Valeo TM15 performance data graph (R134a)

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1-Product description - Performance TM16
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 TM16 performance data table (R134a)
TM16
Nc (r/min) 800 1200 1800 2400 3000
Vol. Eff. (%) 64.9 67.6 65.5 62.9 59.3
Capacity (kW) 2.26 3.53 5.12 6.57 7.74
Power (kW) 1.15 1.78 2.78 3.88 4.90
COP 1.97 1.99 1.84 1.69 1.58
Compressor Speed (rpm)
Volumetric Efficiency (%)
Valeo TM16 performance data graph (R134a)
Cooling Capacity (kW) / Power (kW) / COP

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1-Product description - Swash plate system
Valeo TM08, TM13, TM15 & TM16 are 6 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.
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 horizontal to the drive shaft.
The cylinders, which are arranged at 120° intervals
around the drive shaft, are each divided into 2
chambers providing 3 front and 3 rear bores.
As each piston performs suction and compression at
either end, the compressor operates as a 6 cylinder
compressor.
Radial bearing
Thrust bearing
Suction
CompressionCompression
Suction
Shoe Piston
Radial bearing PistonThrust bearingsDrive shaft Radial bearing Swash plate

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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. 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.