Valeo TM31 User manual

Copyright © 2017 Valeo Japan CO., LTD. All rights reserved.
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.

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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

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1-Product description - Compressor
tc
te
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
te
tc : Condensing temperature
te : Evaporating gas temperature

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※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*

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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 )
Pd
(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
P
Q
• 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

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1- Product description - Dimensions
Unit: mm
Other connecting type
TM31compressors with magnetic clutch
45°
45°
30°
∅
158
∅
156 (effective diameter)
48 48
7999
112
56
38.5
42
21
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

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1- Product description - Exploded view
9
10
8
25
24
23
22
21
20
16
15
7
5
6
3
4
2
1
14
13
12
11
19
17
18
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

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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
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.