Valeo TMX User manual

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)

5
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

9
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.

10
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

11
3 - HANDLING INSTRUCTIONS
Compressor removal
When the compressor is operational
1. Perform the oil return operation (p.11).
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 (p.12).
When the compressor is operational
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 (p.12).
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 at least 20
minutes.
Note: The maximum amount of oil cannot be
recovered at higher speeds. This operation also
requires a warm ambient temperature.

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3 - HANDLING INSTRUCTIONS
Oil quantity inspection
There is no particular need for frequent inspection
or replacement of compressor, although it is
recommended to check operating refrigerant
pressure and oil level at the start of the season.
Please replace the refrigerant and restore the
system oil, 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.
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.
4. The oil easily absorbs moisture when the
container is open. Therefore always seal the
container immediately after use.
Oil contamination
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even if the compressor is run for a
long period (approximately 1 season), 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 specification
Use only VC100YF PAG OIL
Customer can order Valeo service oil package
➝ Part number: T428727 (1 CASE = 6 x 250 cc
can)
WARNING!
When system (oil) contamination is found
during compressor replacement, flush the
A/C system with a fluid that meets SAE
J2670 and replace the dryer (or
accumulator).
Do not mix with other oils !
Cap the container
immediately
●Foreign substances
●Color change
●Metal filings
●Opacity

13
3 - HANDLING INSTRUCTIONS
Oil check
The compressor oil must be checked and
adjusted as follows when replace compressor or
performance system service:
1. Perform the oil return operation (p.11).
2. Remove the old compressor from the vehicle.
3. Drain the oil through both suction and
discharge ports. To drain maximum amount of
oil, with both ports facing down, slowly
position the compressor at different
orientations, then rotate the compressor
armature plate 3 ~ 5 turns. Repeat 2 ~ 3 times.
4. Check the oil for contamination.
5. Adjust the oil amount of the new replacement
compressor per chart below. In case additional
oil need to be added, fill oil through the suction
port (see table below).
CAUTION!
All of the oil cannot be removed when
draining the compressor as some remains as
an oil film on the inside of the compressor
and the system components. Therefore, refer
to the table at left when recharging the
compressor with oil. Excess oil adversely
affects the cooling capacity and the
compressor
Current
compressor is
kept
Compressor is
replaced
Factory
oil
charge
Amount
recovered
Charging
amount
Amount to
remove from
the new
compressor
TMX 130
78 or more Same as
recovered 52
Under 78 78 39
Current
compressor is
kept
Compressor is
replaced
Factory
oil
charge
Amount
recovered
Charging
amount
Amount to
remove from
the new
compressor
TMX 4.6
2.8 or
more
Same as
recovered 1.8
Under 2.8 2.8 1.4
Unit: cm³ & cc
Unit: ounce
Fill the oil through the suction port
Remove used oil from the discharge and suction
ports
CAUTION!
The total amount of oil your air conditioning
system requires is provided by the system
designer or supplier.

14
3 - HANDLING INSTRUCTIONS
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 (p.15).
1. Check that the compressor contains the
specified amount of oil (p.13).
2. Interconnect the suction fitting and the
discharge fitting with the flexible hose.
3. Connect the two connector ports using a
flexible hose
4. Run the compressor at 500r/min for 30
minutes to 60 minutes. This operation may be
performed by an electric motor or the engine
of an automobile.
5. Replace the oil.
6. Repeat the leak test.
CAUTION!
While the compressor is being run-in in step
3 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.
Connect the flexible hoses to suction and
discharge port

15
3 - HANDLING INSTRUCTIONS
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 500 rpm.
Operate the A/C switch through the ON/OFF
cycle at least 50 times (“ON” for 10 seconds
and “OFF” for 10 seconds)
Leak test
The compressor must be checked for refrigerant
leaks after it is repaired. The procedure is as
follows.
1. 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}.
2. Check the compressor for leaks using a
Helium leak detector.
Low
pressure High
pressure
Connect Valve assembly to suction port
ON
OFF
(50 times)

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3 - HANDLING INSTRUCTIONS
Refrigerant charging
Countermeasures to avoid charging with the
wrong refrigerant have been taken. These include
different shaped service valves, different service
tool thread sizes, caution stickers and labels.
In order to prevent a liquid charge and greatly
increase risks of compressor damage, do not
shake or turn the refrigerant bottle upside-down.
Initial Leak Check
Using the leak detector, check the system
connections for leaks.
As the system pressure is not yet high, only large
leaks can be detected at this time.

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3 - HANDLING INSTRUCTIONS
Installation precautions
The new compressor is filled with the specified
quantity of compressor oil and nitrogen gas (N2).
When mounting the compressor on the vehicle,
please follow as below :
1. Loosen the discharge side connector’s cap and
gently release nitrogen gas (N2) from the
compressor.
2. Turn the magnetic clutch armature plate
several times by hand to distribute the oil
which has settled in the cylinders.
3. When installing the compressor in service
system, the compressor should be installed
after adjusting the amount of oil, referring to
“oil check” (p.13)
Armature plate
Discharge Port

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3 - HANDLING INSTRUCTIONS
Piping precautions
1. Position the O-Ring against the bulge in the
pipe when connecting hoses and pipes.
2. Coat the piping connections and the O-rings
with PAG oil.
3. Fit the nuts and unions tightly against the base
of the companion pieces, then hand tighten the
nut as much as possible. Then tighten to the
specified torque.
CAUTION!
Always use the specified oil for HFC-134a
and HFO-1234yf systems to coat the O-rings.
O-ring positions
CORRECT INCORRECT INCORRECT
O-ring Pipe bulge
Apply oil thoroughly to these areas
Piping connection
Compressor / condenser connection
CORRECT INCORRECT
Piping connection procedure
NutUnion
Damage
Gnawing at pipe end

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4 - TROUBLESHOOTING
Compressor troubleshooting
As long as the compressor maintenance is done correctly, there should not be any problem throughout
the whole vehicle life, but should it happen, this troubleshooting can help solving the issue.
Below are listed most of the issues 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 counter 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 recommend that you prepare a gauge manifold to measure
the pressure of both discharge and suction sides (for a detailed diagnosis by gauge pressure, p.24-25).
Compressor troubleshooting tree
1. Insufficient cooling capacity A. Compressor is not running
B. Compressor is running
C. Compressor runs intermittently
A. Abnormal noise from compressor
B. Abnormal noise from magnetic clutch
C. Belt slipping noise
A. Magnetic clutch friction surface slipping
B. Magnetic clutch belt slipping
C. Smoke from magnetic clutch
D. Smoke from compressor
3. Smoke
2. Abnormal noise

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4 - TROUBLESHOOTING
1. Insufficient cooling capacity
A. Compressor
is not running
(no cool blow
coming out)
Replace the compressor
Fix the refrigerant leakage
then fill with refrigerant
until reaching the right
amount
Replace the lead wire if it is
defective
Replace the magnetic
clutch
Replace magnetic clutch
Check the voltage of
battery
Service system and replace
the compressor
Replace compressor if it is
locked
Replace compressor or
magnetic clutch
Compressor internal
damage
Refrigerant shortage
Lead wire short circuit or
wiring connector not
seated properly
Magnetic clutch damage
Magnetic clutch air gap too
wide
Low magnetic clutch
voltage
Thermal fuse activated by
high heat
Belt slipping
Compressor internal part
damage or magnetic clutch
damage
Replace magnetic clutch
Bolt drop off / Armature
drop off
Magnetic clutch slips when
turning on the A/C switch
Low pressure cut switch
operates
The magnetic clutch slips
or does not engage when
the compressor runs
The magnetic clutch
engages but the armature
does not rotate
Belt run off the pulley
Center bolt is loose /
Center bolt is missing
Issue Symptom Potential cause Counter measure