Parts and Service Manual: For KPP15055

PARTS AND SERVICE MANUAL
For KPP15055
DIESEL POWER PACK
INDEPENDENT TRANSIT COMPRESSOR SYSTEM
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TABLE OF CONTENTS

Summary…………………………………………………………………………………………………………………………………….ii
1.0 Transarctic KPP15055 Drawings and Bill of Material
1.1 KPP15055‐ Power Pack, Main Assembly…………………………………………………………………………4
1.2 KPP01510‐ Engine Assembly Kit……………………………………………………………………………..……..5
1.2a ENG30015‐ Engine Modified………………………………………………………………………………………….6
1.3 KPP01520‐ Radiator Assembly Kit………………………………………………………………………..……..…7
1.4 KPP01530‐ Electrical Assembly Kit………………………………………………………………..………….……8
1.5 KPP01540‐ Power Pack Install Kit…………………………………………………………………………..………9
1.6 KPP01560‐ Fuel Assembly Kit……………………………………………………………………………………….10
2.0 VDO TACHOMETER
2.1 Installation……………………………………………………………………………………………………………………11
2.2 Technical Service Bulletin (TB‐333 001)………………………………………………………………………..13
3.0 LOFA MC704 Engine Controller Panel
3.1 Overview………………………………………………………………………………………………………………………14
3.2 Wiring Schematic………………………………………………………………………………………………….………16
3.3 Operation And Troubleshooting………………………………………………………………………………..…20
4.0 Leece Neville 24V/ 150A (8SC3200V) Alternator
4.1 Overview………………………………………………………………………………………………………………………36
4.2 Technical Service Bulletin (TSB‐1031)…………………………………………………………………………..40
4.3 Technical Service Bulletin (TSB‐1105)……………………………………………………………………………41
5.0 Valeo Compressor (Z0015838A)
5.1 Schematic Drawing…………………………………………………………………………………………….…………51
5.2 Service Manual………………………………………………………………………………………….……..………….55
6.0 CAT 1.5L Diesel Engine
6.1 Parts Manual………………………………………………………………………………………………………………111
6.2 Operation Manual………………………………………………………………………………………………………306
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Summary

Transarctic KPP15055 Diesel Power Pack
Caterpillar C1.5 EPA Tier 4 Final
‐Producing 40.2 bhp (30 bkW) and 83 lb/ft (112Nm) of torque at 1800 rpm
‐Meets existing Tier 3/Stage IIIA emission standards for North America and Europe

FEATURES
‐Operation Independent of Vehicle ‐ Only Needs Fuel from Fuel Tank
‐Caterpillar – Reliability, Service and Warranty
‐Dash Mounted Electronic Drivers Control with Hour Meter and Fail‐Safe
‐Remote Operation from Drivers Seat
‐Improved Service Accessibility
‐Service Hatch for Routine Maintenance
‐Removable from bus for Specialized Maintenance
‐Low Profile Design (25” High)

COMPONENTS
‐VDO Tachometer
‐LOFA MC704 Engine Controller Panel
‐Leece Neville 24V/ 150A (8SC3200V) Alternator
‐Valeo Compressor (Z0015838A)
‐CAT 1.5L Diesel Engine
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NOT AVAILABLE

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8 7 6 5 4 3 2 1
3 x2 2
D D
28
30
35
x3 25
C C
NOTES:
17 26
1) USE SERVICABLE THREADLOCKER ON ALL FASTENERS TO ENGINE COMPONENTS
38 22 22 19 X2 15 21 33 37 AND TORQUE ALL BOLTS TO CAT AND/OR S.A.E. SPECIFICATIONS.
x2 15
38 9 EACH WLQ08000 WASHER, LOCK, 1/2", 8, PLT
21 4 37 4 EACH WLP04000 WASHER, LOCK, 1/4", 5, PLT
36 4 EACH WLA12000 WASHER, LOCK, 12mm, 8.8, PLT
33
35 10 EACH WLA10000 WASHER, LOCK, 10mm, 8.8, PLT
37 34 8 EACH WFQ08000 WASHER, FLAT, 1/2", 8, PLT
13
6 33 4 EACH WFN04000 WASHER, FLAT, 1/4", 2, PLT
x2 16 34 32 15 EACH WFA14000 WASHER, FLAT, 14mm, 8.8, PLT
31 4 EACH WFA12000 WASHER, FLAT, 12mm, 8.8, PLT
24
5
29 29 1 EACH TRD08120 THREADED, ROD, 1/2-13UNC x 12", 5 PLT
28 1 EACH TEN80002 TENR, HD SPRING, BACKSIDE, CCW
x4 8 27 1 EACH PUL04021 PULLEY, ALT, IDLER, 4.0"o.d, 2A
x2 12 26 1 EACH PPC15114 POWER PACK, SPACER CUT-OUT, C1.5, '14
20 25 3 EACH PPC15113 POWER PACK, SPACER, C1.5 , '14
38
24 1 EACH PPC15109 POWER PACK, PL, TM-55, C1.5, '14
35
23 1 EACH PPC15103 POWER PACK, WELDM'T CHASSIS, C1.5, '14
22 7 EACH NTQ08000 NUT, HEX, 1/2-13UNC, 8, PLT
21 4 EACH NTP04000 NUT, HEX, 1/4-20UNC, 5, PLT
20 9 EACH NTA10000 NUT, HEX, 10 x 1.5, 8.8, PLT
B 19 1 EACH FDLS-135-1 BREAKER, HIGH AMP, 135 A, RESETTABLE B
x4 10 18 1 EACH ENG30015 ENGINE, DIESEL, CAT 1.5L, 3 CYL, MODIFIED

17 1 EACH CMV33681 TM-55 8PK196 12V AWA *2
31 x15 11 16 2 EACH CLP20028 CLAMP, "P" TYPE, #28, 1/2"W, 1 3/4", PC
15 4 EACH BTS04100 BOLT, HEX, FLG, SER, 1/4-20, 1", 8.2, PLT
36 32
14 1 EACH BTQ08653 BOLT, HEX, 1/2-13UNC x 6.50, 8, PLT
11 15 EACH BTC14121 BOLT, HEX, 14 x 1.5 x 120mm, 10.9, PLT
9 1 EACH BTC10080 BOLT, HEX, 10 x 1.5 x 80mm, 10.9, PLT, FT
35 7 1 EACH BMZ01063 BKT, ALT, PIVOT, SPACER BLOCK, '14
DETAIL A 6 1 EACH BMZ01062 BKT, PL, ALT, TENSION ADJUSTER, '14
30 A SCALE 1 /3 1 5 2 EACH BMZ00029 BKT, UNIVER, HOSE/CABLE, MT, U/S CHASSIS
20 27 4 2 EACH BMT10011 BKT, TENR, BLOCK, OFFSET, 3mm
3 1 EACH BEL81232 BELT, 8GR, 1232mm (48.5")(5080485)
x2 8
2 2 EACH BEL10686 BELT, A GR, 686mm (27") (15270)
1 1 EACH ALT24150 ALTERNATOR, L-N, 24V, 150A
ITEM QTY U/M PART NUMBER DESCRIPTION
BILL OF MATERIALS
TRANSARCTIC INC.
23 DRAWN
jrodriguez 4/9/2014
CHECKED
James Stewart 4/9/2014 TITLE
A 0 . RELEASED TO PRODUCTION. 4/9/2014 JRR QA A
REV: ECN: DESCRIPTION: DATE: BY: James Stewart 4/9/2014
TORQUE SPECIFICATIONS MFG
38 34 34 22 13 38 22 22 4 38 34 13 x2 14 22 34 34 38 7 ITEM SIZE TORQUE
THIS DRAWING CONTAINS PROPRIETARY CONFIDENTIAL INFORMATION
OWNED BY TRANSARCTIC CANADA INC.. THE DOCUMENT AND THE Ron Ingram 4/9/2014 KIT, ENGINE ASSY, C1.5, DIESEL, '14
INFORMATION IN IT ARE NOT TO BE USED, DISCLOSED OR REPRODUCED
8, 9 M10 40-45 FT-LB WITHOUT EXPRESS WRITTEN PERMISSION OF THE COMPANY. APPROVED
10 M12 70-75 FT--LB Dale Mason 4/9/2014 SIZE DWG NO REV
UNSPECIFIED TOLERANCES: [ALT. DIM.]
11 M14 140-145 FT-LB MM [INCH]
12, 13, 14 1/4-13UNC 80-85 FT-LB

ONE DECIMAL PLACE
TWO DECIMAL PLACE
(.X)
(.XX)
.50
.25
[.020]
[.010]
D KPP01510 0
THREE DECIMAL PLACE (.XXX) .10 [.005]
SCALE
15 1/4-20UNC 120-125 IN-LB FRACTIONAL +/- 1/32" ANGULAR +/- .50
THIRD ANGLE PROJECTION DRAWING UNIT OF MEASURE: MM [INCH] 1:4 SHEET 1 OF 1
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
D D
3 1 x2 5 16 18 11 3 2 10 x3 9
DISASSEMBLE AND RELOCATE OEM AIR FILTER.

ORIENTATE ITEM 11 TO ALIGN WITH AIR FILTER MOUNTING HOLES.
REUSE EXISTING OEM FASTENERS.
QTY. (2)
12
C C
REUSE EXISTING OEM FASTENERS. x3 7

QTY.(4)
17
19
REUSE EXISTING OEM GEAR CLAMP.

13
NOTES:
x2 4 1) USE SERVICABLE THREADLOCKER ON ALL FASTENERS TO ENGINE COMPONENTS

AND TORQUE ALL BOLTS TO CAT AND/OR S.A.E. SPECIFICATIONS.
16
B 19 3 EACH WLQ06000 WASHER, LOCK, 3/8", 8, PLT B
18
8 18 4 EACH WLA08000 WASHER, LOCK, 8mm, 8.8, PLT
17 3 EACH WFN06000 WASHER, FLAT, 3/8", 2, PLT
15 1 EACH TUS02006 TUBE, STL, EXH, 2" O.D, STRAIGHT, 6.0"
14 1 EACH PUL15001 PULLEY, CRANK, P8/2A Gr, C1.5, '14
13 1 EACH PPC15117 BKT, FILTER SUPPORT, PP, '14
12 1 EACH PPC15116 POWER PACK, WELDM'T, OUTLET EXHAUST, '14
11 1 EACH PPC15115 THERMOSTAT HOUSING BLOCK CAT 1.5L
15 10 1 EACH PPC15110 POWER PACK, PL, TENSIONER MOUNT, C1.5, '14
9 3 EACH CSF06125 CAPSCREW, FH, 3/8-16 x 1.25", 9, PLT
8 2 EACH CLP36001 CLAMP, GEAR, #36, 1 13/16- 2 3/4, (46/70mm)
7 3 EACH BTQ06125 BOLT, HEX, 3/8-16UNC, 1.25", 8. PLT
6 8 EACH BTQ05125 BOLT, HEX, 5/16-18UNC, 1.25", 8 PLT
8 14 x8 6 4 2 EACH BTC08025 BOLT, HEX, 8 x 1.25 x 25mm, 10.9, PLT
3 2 EACH 439-0945 WATER OUTLET GASKET
2 1 EACH 303-4102 ENGINE, DIESEL, CAT 1.5L, 3 CYL
1 1 EACH 139-6C FTG, 90 ELB, 3/8" BARB TO 3/8 NPT, BRASS
REUSE EXISTING OEM AIR FILTER HOSE.
CUT HOSE SQUARE ON IN MIDDLE, ITEM QTY U/M PART NUMBER DESCRIPTION
REUSE EXISTING OEM GEAR CLAMP.
AND ORIENTATE BOTH PIECE TO BILL OF MATERIALS
TRANSARCTIC INC.
SUIT INSTALLATION. DRAWN
jrodriguez 4/9/2014
CHECKED
Val Jakowlew 4/9/2014 TITLE
A 0 . RELEASED TO PRODUCTION. 4/9/2014 JRR QA A
REV: ECN: DESCRIPTION: DATE: BY: James Stewart 4/9/2014
MFG ENGINE, DIESEL, CAT 1.5L, 3 CYL,
OWNED BY TRANSARCTIC CANADA INC.. THE DOCUMENT AND THE Ron Ingram 4/9/2014
TORQUE SPECIFICATIONS INFORMATION IN IT ARE NOT TO BE USED, DISCLOSED OR REPRODUCED
WITHOUT EXPRESS WRITTEN PERMISSION OF THE COMPANY. APPROVED MODIFIED
ITEM TORQUE Dale Mason 4/9/2014 REV
UNSPECIFIED TOLERANCES:
SIZE DWG NO
4, 5 40-45 FT-LB MM
[ALT. DIM.]
[INCH]
6 236 IN-LB
ONE DECIMAL PLACE
TWO DECIMAL PLACE
(.X)
(.XX)
.50
.25
[.020]
[.010]
D ENG30015 0
SCALE
7 35 FT-LB FRACTIONAL +/- 1/32" ANGULAR +/- .50
8 7 6 5 4 3 2 1
8 7 6 5 4 3 2 1
x 17 8 7 9
1 10 x 2 11
H H
G G
F F
2 x 17
4 x3
E E
D D
x 2 14
C C
19 6 EACH BTQ06100 BOLT, HEX, 3/8-16UNC, 1", 8. PLT

18 6 EACH WFS06001 WASHER, FLAT, WIDE, 3/8", 8, PLT
16 6 EACH WLP06000 WASHER, LOCK, 3/8", 5, PLT
15 15 1 EACH 240-B FTG, DRAIN COCK, 1/4" MPT, BRASS
14 2 EACH 121-B FTG, PIPE, PLUG, HEX HD, 1/4 MPT, BRASS
B B
13 4 FT IRE10B34 TRIM, 9/16" x 1/8", BLACK, PEBBLE, ALUM
12 6 EACH J-11729-177 RAD, SANDWICH MOUNT, TYPE 2, 3/8-16UNC
11 2 EACH BMZ01064 BKT, PL, "P" CLAMP, SUPPORT, '14
10 1 EACH 125-6B FTG, STR, 3/8" BARB TO 1/4" NPT, BRASS
8 17 EACH BTP04100 BOLT, HEX, 1/4-20UNC, 1", 5, PLT
6 1 EACH PPC15208 BKT, WELDM'T, RAD FRAME, CAT 1.5L
5 1 EACH PPC15207 RAD SHROUD WELDMENT CAT 1.5L
4 3 EACH CLP20016 CLAMP, "P" TYPE, #16, 1/2"W, 1", PC
3 3 EACH FAN60003 FAN, COND, 12V, 2490 M3/HR, (1469 CFM)
2 17 EACH NTS04001 NUT, RIV, 1/4-20 UNC
1 1 EACH RAD15010 RADIATOR, POWER PACK, C1.5L, 50x18x4
Parts List
TRANSARCTIC INC.
DRAWN
Klarin 3/26/2014
CHECKED
. James Stewart 3/26/2014 TITLE

A RELEASED TO PROTOTYPE 3/28/2014 KEV QA
A A
REV: ECN: DESCRIPTION: DATE: BY: JRodriguez 3/26/2014
MFG KIT, RAD, ASS'Y, 3 FAN, 12V, PP EXP.
OWNED BY TRANSARCTIC CANADA INC.. THE DOCUMENT AND THE VJakowlew 3/26/2014
WITHOUT EXPRESS WRITTEN PERMISSION OF THE COMPANY. APPROVED VIEW
x 4 13 5 x 6 19 18 17 16 12 x3 3
Dale Mason 3/26/2014 SIZE DWG NO REV
MM [INCH]
ONE DECIMAL PLACE
TWO DECIMAL PLACE
(.X)
(.XX)
.50
.25
[.020]
[.010] E KPP01520 A
SCALE
FRACTIONAL +/- 1/32" ANGULAR +/- .50 ~ THIRD ANGLE PROJECTION DRAWING UNIT OF MEASURE: MM [INCH] 1 :5 SHEET 1 OF 1
8 7 6 5 4 3 2 1

NOT AVAILABLE

AT THIS TIME
www.Transarctic.com
REV 0
8 7 6 5 4 3 2 1
D D
x2 2 x2 4 1 10 x2 9 11 16 20 22
C C
10
14
NOTES:
18 1) USE SERVICABLE THREADLOCKER ON ALL FASTENERS TO ENGINE COMPONENTS

AND TORQUE ALL BOLTS TO CAT AND/OR S.A.E. SPECIFICATIONS.

10 21 1 EACH WLA08000 WASHER, LOCK, 8mm, 8.8, PLT
B B
9 18 1 EACH SCD12708 SPACER, COL, DRL, 12.7mm x 25.4o x 8.33i
17 1 EACH PPC15600 BKT, FUEL SYSTEM KPP15055
12 16 3 EACH NTS04001 NUT, RIV, 1/4-20 UNC
16 15 1 EACH NTA08000 NUT, HEX, 8 x 1.25, 8.8 PLT
14 2 EACH HOF03100 HOSE, FUEL, 5/16", DAYCO x 2.25"L.
20 13 1 EACH HOF03100 HOSE, FUEL, 5/16", DAYCO x 6.00"L.
12 1 EACH CLP20028 CLAMP, "P" TYPE, #28, 1/2"W, 1 3/4", PC
22
11 2 EACH CLP20016 CLAMP, "P" TYPE, #16, 1/2"W, 1", PC
10 8 EACH CLP06001 CLAMP, GEAR, #6, 3/8-3/4 (10-20mm), S
9 3 EACH BTS04100 BOLT, HEX, FLG, SER, 1/4-20, 1", 8.2, PLT
7 1 EACH 276-1804 CAT, C1.1, FILTER, WATER SEPARATOR
10 13 10 10 6 17 6 1 EACH 243-6411 COARSE OIL FILTER
5 10 14 10 21 19 18 15 8 7
5 1 EACH 197-8540 CAT, C1.1, PRIME BULB
4 2 EACH 1495-SB FTG, TERMINAL BOLT, 1/4" FPT ENDS, BRASS
3 1 EACH 125-5B FTG, STR, 5/16" BARB TO 1/4" MPT, BRASS
BILL OF MATERIALS
TRANSARCTIC INC.
DRAWN
Klarin 3/24/2014
CHECKED
. James Stewart 3/24/2014 TITLE

A 0 RELEASED TO PRODUCTION 3/24/2014 JRR QA A
REV: ECN: DESCRIPTION: DATE: BY: JRodriguez 3/24/2014
MFG BKT, FUEL SYSTEM, KPP15055,
OWNED BY TRANSARCTIC CANADA INC.. THE DOCUMENT AND THE VJakowlew 3/24/2014
WITHOUT EXPRESS WRITTEN PERMISSION OF THE COMPANY. APPROVED EXPLODED VIEW
Dale Mason 3/24/2014 SIZE DWG NO REV
MM [INCH]
ONE DECIMAL PLACE
TWO DECIMAL PLACE
(.X)
(.XX)
.50
.25
[.020]
[.010]
D KPP01560 0
SCALE
FRACTIONAL +/- 1/32" ANGULAR +/- .50
8 7 6 5 4 3 2 1
Use this table if you
➊ BEGIN HERE
Clamp over the back of the instrument. Its
direction depends on the thickness of the
panel (Diagram B). Tighten the clamp un-
are using your tachom- til the gauge can no longer be rotated by
eter with an ignition CAUTION: Read these instructions hand.
coil. thoroughly before making installation. DO NOT OVERTIGHTEN.
Do not deviate from assembly or wiring
instructions. Always disconnect battery
Use this table if your ignition ground before making any electrical Tachometer Wiring:
is the type that provides a connections. If in doubt, please contact
pulse-per-revolution type your dealer or VDO Instruments at (800) 1. Run wires from the tachometer loca-
signal. 265-1818. tion to:
4000 RPM Alternator Tach a) A +12 volt power terminal.
2:1 ratio set for 6 cyl. gas;
(This positive power source
use pot to calibrate. Tachometer Installation:
MUST BE SWITCHED, and
should be protected with a fuse);
Diagram D 1. Select the location where you will mount
Tachometer configuration for use with ignition coil (top); alternator (bottom) the gauge, and cut a 2 ¹⁄₁₆" hole as shown b) the light switch (also after the
in Diagram A. fuse in the fuse box);
2. Slip the VDO Spin-Lok Mounting c) a good ground location;
➊ Compare the VDO Tachometer [text continues at # Ë] Ù
reading with that of a reference
tachometer.
➌ The pointer will move clockwise or

counterclockwise as you adjust. CAUTION!!! Parts List
When the VDO Tachometer reading Item Description Quantity
matches that of the reference The bezel diameter is only a few mil- 1. Tachometer
tachometer, the limeters larger than the gauge itself.
➋ Adjust the
(2 ¹⁄₁₆" [52 mm] diameter) 1
adjustment is complete. 2. Lamp Socket (Push in, wedge-type) 1
With that in mind, measure and pre-
potentiometer 3. Light Bulb (12-volt / G.E. #158 or equivalent) 1
on the side cisely mark the gauge location be- 4. VDO Spin-Lok™ Clamp 1
of the gauge. fore cutting any holes! 5. Installation Instructions 1
Diagram E
Fine tachometer adjustment needed when using a pulse-per-revolution signal Tools and Materials Needed For Installation:
16 Gauge stranded, insulated wire
Non-insulated ¼" spade connectors
2 ¹⁄₁₆" hole saw Tachometer
Drill and drill bit set Installation Instructions
Half-round file Instruction Sheet #0 515 012 044
Rev. 10/09
Tape measure or ruler INSTRUCTIONS FOR THE INSTALLATION OF THE TACHOMETER ARE CONTAINED
Small tools: wrench or nut driver, utility HEREIN. USE IS RESTRICTED TO 12-VOLT NEGATIVE GROUND ELECTRICAL
SYSTEMS. LIGHT BULB, IF SUPPLIED, IS 12 VOLT.
knife, pliers, etc.

To Begin, go to #➊
PP ➋ CONTINUE HERE another type of ignition system, determine
the number of pulses per revolution the
ignition signal provides, and set the DIP
d) the location of the signal source switches as shown in the bottom table.
é PP
(alternator, coil or other ignition
PP
signal source).
Adjusting the Tachometer Pointer:
2. Connect the wiring to the appropriate
tachometer terminals as shown in Diagram Use of the VDO Tachometer with an al-
C. ternator or other type of ignition that pro-
vides a signal in pulses per revolution may

requre calibration of the pointer.

Configuring the Tachometer:

This can be done as show in Diagram E.

Before your VDO Tachometer will func- Please note that this calibration is designed
tion properly with your engine, you will to adjust the reading between 30% and
need to configure it as shown in Diagram
PP D.
100% of the RPM range.
At this point, the installation and wiring
PD[ PP The table at the top of Diagram D shows of your new VDO Tachometer is complete.
how to set the DIP switches for use with Turn on the ignition and the lights in the
an ignition coil; the table at the bottom
Mounting hole dimension = 2¹⁄₁₆" (52 mm) shows how to set the DIP switches when
car and check to see that the instrument
and light work properly. If they dont, re-
using the tachometer with an alternator. check your wiring, referring to the wiring
Diagram A When using the VDO Tachometer with description in Diagram C.
Gauge dimensions
DQSX_]UdUb DQSX_]UdUb 7b_e^T

7b_e^T 7b_e^T
7b_e^T

13DQ`
<YWXd DUb]Y^Q\!_b° <YWXd
CgYdSX CgYdSX
6ecU
2_h
&2,/
CgYdSXUT CgYdSXUT
!"f 2QddUbi !"f 2QddUbi
Mounting Nut direction
depends on panel width 1\dUb^Qd_b 9W^YdY_^3_Y\
A: 0 .4" (0 10 mm)
B: .4" .8" (10 20 mm)
Diagram B Diagram C
Proper mounting using VDOs Spin-Lokä Mounting Clamp Tachometer wiring with Alternator AC Tap (left); and with Ignition Coil (right)
Technical Bulletin
No. TB-333 001
Product: Description Date

Tachometer Aug 03
Type: ERRATIC OPERATION Issue
Electrical 1
To Reduce or Eliminate Erratic Operation in Tachometers
1. Purchase diode #1N4005 from your local electronics store.
2. Cut both ends of the diode so each is approx. 3/ 4" long.
3. Crimp a 1/ 4" female spade connector on the end of the diode with the
silver band.
4. Crimp a butt-splice connector on the other end of the diode.
5. Crimp the opposite end of the b utt-splice connector to the wire connected
to ignition signal source.
6. Connect 1/ 4" female spade connector used in step # 3 above to terminal

# 4 on the back of the tachometer.
7. Connect a ground (-) wire to terminal # 3.
8. Connect a switched 12-volt power wire to terminal # 2.
9. Set switches for the appropriate number of cylinders.
Page 1 of 1
Copyright by Siemens VDO 2003 All rights reserved
THIS IS A NON-CONTROLLED DOCUMENT

MC704 SERIES MICRO CONTROL PANEL
FOR MECHANICALLY GOVERNED ENGINES
The LOFA MC704 Series is a compact micro panel that

controls, monitors and protects mechanically governed
diesel engines.
MC704 FEATURES
• Rugged powder-coated aluminum housing
• Automatic shutdown bypass during starting
• Hour meter (on MC704HP)
• Microprocessor–based control designed with high power

semiconductors
• First-Fault Diagnostic (FFD) LED pinpoints initial failure

–– OK/Preheat
–– Alternator charge failure MC704 HP Micro Panel With Hour Meter
–– Low oil pressure
–– High coolant temperature
–– AUX switch
• Thru-panel or threaded inserts mounting
• Reverse polarity protection
• Heavy-duty IP64 key switch with booted key
• Key switch features mechanical lock-out to prevent re-start attempts

when engine is running
• 12” connection pigtail terminating at a Delphi GT connector
MC704 LCP Micro Panel Without Hour Meter
250 Hembree Park Drive, Suite 122

Roswell GA 30076
Phone: 770 569 9828
Fax: 770 569 9829
Delphi GT weather-proof connector on standard 12” wiring harness.
Other electrical connections available on request. www.LOFA.net
Advanced Engine Control Technology

MC704 OPTIONS
• Plug-and-play harnesses
• Flip-down key switch cover
• Alarm or preheat control output (active high)
MC704 WARRANTY
• 2 Year Limited Warranty
MC704 DIMENSIONS
MC704 SPECIFICATIONS
Voltage - System Nominal 10-28 VDC

Operating Temperature -20F to 185F (-30C to 85C)
Reverse Polarity Protection Yes

Starter Relay Suggested
Solid State I/O:
Fuel Solenoid 20A

Switched Battery 15A
Starter 50A@1sec; 12A
Alarm Output 3.5A
Advanced Engine Control Technology
©2013 LOFA Industries, Inc. LOFA Industries, Inc. is constantly striving to improve its products and must therefore reserve the right to change designs,
materials, specifications and prices without notice. Printed in the USA. 7/13
MC-704 SERIES SCHEMATIC
WITHOUT PREHEAT
MC 704 - LC / H
704 J1
OIL PSI N/C (GREEN)
1
D+ ALTERNATOR (WHITE)
2
TEMPERATURE N/O (BROWN)
3
AUX. SW. N/O (GRAY)
4
GROUND (DARK BLUE)
5
SOLENOID (BLACK)
6
ALARM OUTPUT OPTIONAL(YELLOW)
7
KILL SWITCH (OPTIONAL)
8
704 SW.
50 STARTER MOTOR (PURPLE)
30
AUX. SWITCH N.O.

15 KEY SWITCH (RED)
MAX. 3.5A
BATTERY (TAN)
MAX. 3.5A
1N4007
DIODE WK G
8 AWG CHARGE
WIRE
D+ B+ W WK G
+ P
30 50
G
FUSE
-
M
TEMP. LUBE OIL
- 31 BOSCH ALTERNATOR SENSOR/SWITCH
PRESSURE
+
SOLENOID GROUND N./O.

OPTIONAL STARTER MOTOR SENSOR/SWITCH
BATTERY KILL SWITCH N./C.
ENGINE AND USER SUPPLIED WIRING
REDUCING VOLTAGE SPIKES

High Voltage spikes up to 1000V or more can occur momentarily when a relay or solenoid is
switched off. Relay contacts, electronics, etc. can be damaged or malfunctions can occur if these
KEY SWITCH ELECTRICAL DIAGRAM
spikes reach the electrical network without suppression. A 1N4007 diode should be used when using POS. 0 I II CURRENT
any of LOFA’s products. Please install this diode as close as possible to the solenoid. Please note
installing the diode incorrectly or reversing the polarity of the battery will damage the diode. 30 - 83 2A
30 - 75 20 A
BLACK 16 AWG TO 704 #6
30 - 15 25 A
50 A
RED 16 AWG TO 15
RED 16 AWG TO 15
30 - 50 12 A
WHITE 16 AWG
WHITE 16 AWG
1N4007
Hold
DIODE
TO 704 #2
TO 704 #2
Pull
CHARGE WIRE CHARGE WIRE
1 2 B+ R IG L B+ R
3-WIRE SOLENOID 30 50 + +
WIRING DIAGRAM G G
- -
31 DELCO ALTERNATOR KUBOTA ALTERNATOR

STARTER MOTOR
PHONE 770 569 9828 FAX 770 569 9829 www.LOFA.net

©2002 LOFA Industries, Inc. LOFA Industries, Inc. is constantly striving to improve its products and must therefore
reserve the right to change designs, materials, specifications and prices without notice. Printed in the USA. 9/03 250 Hembree Park Drive Suite 122 Roswell GA 30076
WITH PREHEAT
MC 704 - LC / H
704 J1
OIL PSI N/C (GREEN)
1
2
3
4
GROUND (DARK BLUE)
5
SOLENOID (BLACK)
6
PREHEAT (YELLOW)
7
8
704 SW.
30
15 KEY SWITCH (RED)
MAX. 3.5A
BATTERY (TAN)
MAX. 3.5A
1N4007
DIODE WK G
8 AWG CHARGE WIRE G
FUSE D+ B+ W WK
+ P
30 50
G
FUSE
86 87 GLOW PLUG -
M
87a LUBE OIL
30 TEMP. PRESSURE
85
- 31 BOSCH ALTERNATOR SENSOR/SWITCH SENSOR/SWITCH
+
POWER RELAY SOLENOID GROUND N./O.

OPTIONAL STARTER MOTOR N./C.
BATTERY KILL SWITCH
PREHEAT INDICATION
VIA MC704 AUX LED

High Voltage spikes up to 1000V or more can occur momentarily when a relay or solenoid is
switched off. Relay contacts, electronics, etc. can be damaged or malfunctions can occur if these POS. 0 I II CURRENT
spikes reach the electrical network without suppression. A 1N4007 diode should be used when using
any of LOFA’s products. Please install this diode as close as possible to the solenoid. Please note 30 - 83 2A
installing the diode incorrectly or reversing the polarity of the battery will damage the diode. 30 - 75 20 A
BLACK 16 AWG TO 704 #6 30 - 15 25 A
50 A
RED 16 AWG TO 15
RED 16 AWG TO 15
30 - 50 12 A
WHITE 16 AWG
WHITE 16 AWG
1N4007
Hold
DIODE
TO 704 #2
TO 704 #2
Pull
1 2 B+ R IG L B+ R
+ +
3-WIRE SOLENOID 30 50 G G
WIRING DIAGRAM
- -
M
DELCO ALTERNATOR KUBOTA ALTERNATOR
31
STARTER MOTOR

WITH PREHEAT AND AUXILIARY SHUTDOWN
MC 704 - LC / H
704 J1
OIL PSI N/C (GREEN)
1
2
3
AUX. SW. N/O (GRAY)
4
GROUND (DARK BLUE)
5
SOLENOID (BLACK)
6
PREHEAT (YELLOW)
7
8
704 SW.
30
AUX. SWITCH N.O.

15 KEY SWITCH (RED)
MAX. 3.5A
BATTERY (TAN)
MAX. 3.5A
1N4007 DIODE WK G
FUSE 8 AWG CHARGE WIRE D+ B+ W WK G
+ P
30 50
G
FUSE
86 87 GLOW PLUG -
M
30 87a LUBE OIL
85 TEMP. PRESSURE
- 31 BOSCH ALTERNATOR SENSOR/SWITCH
SENSOR/SWITCH
+
POWER RELAY SOLENOID GROUND N./O.

OPTIONAL STARTER MOTOR N./C.
BATTERY KILL SWITCH
PREHEAT INDICATION
VIA BLINKING MC-704
GREEN LED

High Voltage spikes up to 1000V or more can occur momentarily when a relay or solenoid is KEY SWITCH ELECTRICAL DIAGRAM
switched off. Relay contacts, electronics, etc. can be damaged or malfunctions can occur if these
spikes reach the electrical network without suppression. A 1N4007 diode should be used when using POS. 0 I II CURRENT
any of LOFA’s products. Please install this diode as close as possible to the solenoid. Please note
30 - 83 2A
installing the diode incorrectly or reversing the polarity of the battery will damage the diode.
30 - 75 20 A
30 - 15 25 A
RED 16 AWG TO 15
RED 16 AWG TO 15
50 A
30 - 50 12 A
WHITE 16 AWG
WHITE 16 AWG
1N4007
Hold
DIODE
TO 704 #2
TO 704 #2
Pull
1 2 B+ R IG L B+ R
+ +
3-WIRE SOLENOID 30 50
WIRING DIAGRAM G G
- -

31
STARTER MOTOR

WITH PREHEAT AND OVER-SPEED
MC 704 - LC / H
704 J1
OIL PSI N/C (GREEN)
1
2
3
4
GROUND (DARK BLUE)
5
SOLENOID (BLACK)
6
PREHEAT (YELLOW)
7
OVER-SPEED SHUTDOWN SIGNAL (GREEN/GREY)
8
OVER-SPEED INDICATION VIA

704 SW.
BLINKING BATTERY LED
30
15 KEY SWITCH (RED)
MAX. 3.5A
BATTERY (TAN)
MAX. 3.5A
1N4007
DIODE WK G
8 AWG CHARGE WIRE G
FUSE D+ B+ W WK
+ P
30 50
G
FUSE
86 87 GLOW PLUG -
M
30 87a
85 TEMP. LUBE OIL
- 31 BOSCH ALTERNATOR SENSOR/SWITCH PRESSURE
+
POWER RELAY GROUND N./O.

STARTER MOTOR SHUTDOWN SENSOR/SWITCH
BATTERY SOLENOID N./C.
PREHEAT INDICATION
VIA MC-704 AUX LED

High Voltage spikes up to 1000V or more can occur momentarily when a
relay or solenoid is switched off. Relay contacts, electronics, etc. can be POS. 0 I II CURRENT
damaged or malfunctions can occur if these spikes reach the electrical
30 - 83 2A
network without suppression. A 1N4007 diode should be used when using any
GREEN/GREY 16 AWG TO 704 #8
GREEN/GREY 16 AWG TO 704 #8
of LOFA’s products. Please install this diode as close as possible to the 30 - 75 20 A

solenoid. Please note installing the diode incorrectly or reversing the polarity
30 - 15 25 A
of the battery will damage the diode.
50 A
30 - 50 12 A
RED 16 AWG TO 15
RED 16 AWG TO 15
WHITE 16 AWG
WHITE 16 AWG
1N4007
Hold
DIODE
TO 704 #2
TO 704 #2
Pull
1 2 B+ R IG L B+ R
+ +
3-WIRE SOLENOID 30 50 G G
WIRING DIAGRAM
- -
M
31
STARTER MOTOR

LOFA MC704 and MC704 G4 Operation and Troubleshooting
Introduction
This document provides general information on LOFA Industries MC704 control systems operation and
troubleshooting. MC704 control systems are a very flexible platform for diesel engine control, monitoring,
and protection, featuring LOFA’s powerful First Fault Diagnostics (FFD). After pinpointing the initial failure,
FFD stores it in memory and alerts the end user via a single bright LED. FFD monitors battery charge, low oil
pressure, high temperature and one additional contact closure input. The microprocessor-based solid-state
design uses high-power semiconductors instead of outdated electromechanical relays to ensure reliable
high-current switching.
The MC704 panels are offered in two versions. The MC704HP has a built-in tamperproof LED hourmeter
while the reduced cost MC704LCP eliminates the hourmeter. The G4 variant includes up to four 2 inch
gauges. All panel versions can be factory configured with specific preheat & afterglow requirements. If
preheat is not required, this output can function as an alarm.
All standard panels include feature a 12 inch wiring harness terminating into a sealed weather proof plug.
This robust universal wiring connection performs well in harsh environments and allows interchanging a
number of different panels and harnesses. This design allows for simplified installation as well as a flexible
means to incorporate custom plug-and-play engine wiring harnesses and standard harness extension
Note
The engine harness is not included with the panel.
A number of standard engine harnesses are available or

LOFA can develop a custom harness for you exact needs.
Generic harnesses in various lengths are available for field customization.
Warning
When replacement parts are required, LOFA Industries recommends using replacement parts
supplied by LOFA or parts with equivalent specifications.
Failure to heed this warning can lead to premature failure,

product damage, personal injury or death.
463-3000-02 Rev C.2 - 15-April -2008 1

Important Safety Information

The warnings in this publication are not all inclusive.
LOFA Industries cannot anticipate every potential hazard.
Appropriate safety rules and precautions should be followed with any

tool, work method or operating procedure.
Improper procedures, tools and materials may cause

damage or make the equipment unsafe to operate.
Only persons with appropriate training, skills and tools

should perform these functions.
Improper operation, maintenance or repair of this product can be

dangerous and may result in injury or death.
Do not operate or perform any maintenance or repair on this product until all operation,
maintenance and repair information is read and understood.
The information, specifications, and illustrations in this publication are based on information
available at the time of publication.
All items are subject to change at any time without notice.
2 463-3000-02 Rev C.2 15 -April - 2008

Operation
Turning the control system key to the run position starts a self-test which causes all LEDs to flash three times,
activates the alarm output (if preheat is not used) for one second and enables the fuel run/stop solenoid
output. After self-test, the LEDs indicate the state of the inputs they monitor. The normal indications are
battery charge and oil pressure on most applications. If these LEDs are not illuminated at this time it may
indicate the inputs are not properly connected.
The Preheat/OK LED begins to blink when the key switch is turned to the run position if automatic preheat is
configured (See Preheat Options). Preheat time varies from application to application. After waiting for the
Preheat/OK LED to become solid, the engine is cranked by turning and holding the key switch in the start
position until the engine starts. The key switch is spring loaded to return automatically to the run position
when released.
Note
The key switch is equipped with a mechanical start locking device.
An attempt to re-crank the engine can only be made by turning the key switch
to the off position to reset the start locking mechanism.
If the engine is not started within 30 seconds of turning on the system, the fuel run/stop solenoid output is
turned off to prevent battery discharge when the key switch is left in the run position. The fuel run/stop
solenoid output is turned off after 30 seconds even if preheating. As soon as the key switch is turned to the
start position the solenoid output is enabled. The afterglow cycle begins when the key switch returns to the
run position.
Note
If conditions do not warrant preheat, the engine may be started by turning the key to the start
position without waiting for the preheat time to expire.
Control system instrument power, including the hourmeter and voltmeter, is provided by the fuel run/stop
solenoid output. If the instruments do not power up when the key is turned to the run position, this indicates
a problem with the solenoid circuit (see Troubleshooting).
After the engine starts, the control system electronics ignore all shutdown conditions for the first 10 seconds.
This delay eliminates the requirement to hold a by-pass override button during starting and allows the system
conditions such as oil pressure to normalize. The 10 second timer starts when the key switch returns to the
run position.
Note
Starter input is required for correct system operation. If the starter motor input is not activated
(connected to battery positive) and the engine is started through another means (i.e. air
starter) the engine will shutdown 30 seconds after the key switch is turned to the run position.
To prevent unintentional engine shutdowns caused by intermittent conditions (i.e., pressure spikes, coolant
movement) the control system requires a constant 1/3 second fault input to cause engine shutdown.
Warning
When used in combination with mechanical float type switches
engine vibrations may prevent constant contact closure.
463-3000-02 Rev C.2 - 15- April-2008 3
Preheat Options
Preheat Output
Preheat is a 3A positve output for control of an external power relay with predetermined preheat and
afterglow times. A relay should be selected with appropriate amperage capacity for the installed cold starting
aid (glowplug, intake air heater, etc.). Applications using multiple cold starting aids may require multiple
relays.
Note
Consult engine documentation when selecting cold starting aid,
power relay and heating specifications.
Indicators
Battery LED (Red)

A solidly illuminated Battery LED indicates a battery charge failure. A battery charge failure may be caused
by a faulty alternator, broken drive belt or the alternator not excited. A battery voltage reading of
approximately 14 volts on a 12 volt system (28 volts on a 24 volt system) while the engine is running
indicates the battery is charging properly. Irregular blinking of the Battery LED may indicate a failing charge
circuit. The system can be configured for battery charge failure to indicate only.
Oil Pressure LED (Red)

A solidly illuminated Oil Pressure LED indicates low oil pressure failure. The control system typically senses
low oil pressure from a ground contact switch on the engine. When a sender/switch combination is used on
the engine, the marking WK generally indicates the switch terminal. This input typically expects a normally
closed switch (ground contact when oil pressure is low). A defective switch or shorting the shutdown input to
ground can cause low pressure fault indication. Additionally, when using sender/switch combinations,
swapping the WK and G terminal can cause unintended shutdowns. The system can be configured for oil
pressure failure to indicate only.
Warning
Low oil pressure is not an indication of low oil level.
For best possible protection LOFA recommends using

our solid-state oil level shutdown switch.
Note
Most shutdown switches are grounded through the switch body.
Do not use insulating sealant (i.e. Teflon tape) when installing switches.
Temperature LED (Red)

A solidly illuminated Temperature LED indicates high engine temperature failure. The control system typically
senses high temperature from a ground contact switch on the engine. When a sender/switch combination is
used on the engine, the marking WK or W generally indicates the switch terminal. This input typically expects
a normally open switch (ground contact when engine temperature is too high). A defective switch or shorting
the shutdown input to ground can cause over temperature fault indication. Additionally, when using
4 463-3000-02 Rev C.2 -15-April-2008
sender/switch combinations, swapping the WK or W and G terminal can cause unintended shutdowns. The
system can be configured for temperature failure to indicate only.
Warning
If the temperature switch is not in contact with coolant due to
coolant loss the engine is not protected from overheating.
For best possible protection, LOFA recommends using

our solid-state coolant level shutdown switch.
Note
Some thermostat housings are composites and do not provide ground for the switch.
AUX LED (Red)

A solidly illuminated AUX LED indicates an auxiliary failure (i.e., coolant level, oil level, belt breakage,
hydraulic pressure, etc.). The control system typically senses failure using a ground contact switch. Auxiliary
inputs are equipment specific and determined by the equipment manufacturer. A defective switch or shorting
the shutdown input to ground can cause fault indications. The system can be configured for auxiliary failure
to indicate only.
Preheat/OK LED (Green)

A blinking green Preheat/OK LED is the system preheat indication. When the LED changes to solid the
preheat period is complete and the engine may be cranked. The LED changes to solid illumination when the
engine starts. There is no indication of afterglow.
463-3000-02 Rev C.2 -15-April-2008 5

Harness
Sealed Connectors
The provided sealed weather proof plug includes a grey locking device which must be released to separate
the connectors. Press the tab on the connector housing to release the connectors.
Warning
LOFA does not recommend using dielectric grease or sealant with sealed connectors.
These chemicals may cause seal damage and allow water entry.
Use LOFA provided cavity plugs to seal the connector if wires are removed.
Unsealed Connectors
For unsealed connectors exposed to the elements, LOFA recommends using dielectric grease to protect
contacts.
Warning
LOFA does not recommend using sealant with unsealed connectors.
Sealant traps moisture in the connector and encourages corosion.
Harness Routing
The minimum routing of radius of the wiring harnesses should be at least two times the diameter of the
wiring harness. Bends should be avoided within 1 inch (25 mm) of any connector in order to avoid seal
distortion allowing moisture to enter the connector.
Note
For harness length in excess of 10 ft a relay must be added to the start solenoid circuit.
LOFA offers starter relay kits for mounting near the engine.
6 463-3000-02 Rev C.2 -15-April-2008

Battery Circuit Requirements

Battery Positive Connection
The electronic control system operates on either a 12 VDC or 24 VDC electrical systems. The unswitched
battery positive connection to the control system is made at the weather proof connector. The control system
provides switched positive battery
Protection for the unswitched battery positive circuit is dependent on specific equipment configuration. The
overload protection should not exceed 125% of the sum of all output currents plus 5 Amps for the control
system. Powering the control system through dedicated circuits with appropriate overload protection reduces
the possibility of system damage.
Circuit breakers are preferred over in-line fuses for circuit protection. Over current protection devices should
ideally be located in a central location. If automatic reset circuit breakers are used, consideration of the
environment of the breaker is critical and may affect the trip point. The trip point of some circuit breakers
can be significantly reduced below the rated trip point if the circuit breaker is exposed to high temperatures.
Warning
Disconnecting the battery while the engine is running
may damage electrical components.
When using a battery disconnect switch, LOFA recommends using a

2 pole switch to disconnect both the battery and alternator output.
Battery Negative Connection (Grounding)

Warning
Improper grounding can cause electrical noise, unreliable operation and may damage the
control system or other components. All ground connections must be free from foreign
materials, including paint, which may interfere with proper grounding.
A reliable ground must be provided for the control system.

LOFA recommends the ground connection be made directly to the battery negative.
Grounding through frame members is not recommended.
All ground paths must be capable of carrying any likely fault currents.
Do not reverse the battery polarity. Attempting to crank the engine when the polarity of the
battery connections is reversed may damage the control system.
Note
A maximum of three ring terminals should be connected to a ground stud in order to ensure
integrity of the ground connection. The use of more than three terminals can cause the
connection to become loose.
Voltage Drop
If control system voltage drops below 6 volts for more than one tenth of a second, the control system may
reset causing the self test to reactivate and the engine to shutdown after 30 seconds. Resetting the control
463-3000-02 Rev C.2 -15-April-2008 7

system is equivalent to quickly turning the key switch to off and back to run without starting the engine. Since
the control system did not sense a start signal, the fuel run/stop solenoid deactivates after 30 seconds.
Voltage drops can be caused by transients from external equipment, improper wire sizes, faulty wiring or
nearby lightning strikes. In the absence of a LOFA Power Box, relays may be needed for long wire runs.
Suppression of Voltage Transients (Spikes)

Warning
The installation of voltage transient suppression at the transient source is required.
LOFA follows SAE recommended electrical environment practices.
Inductive devices such as relays, solenoids and motors generate voltage transients and noise in electrical
circuits. Unsuppressed voltage transients can exceed SAE specifications and damage electronic controls.
Relays and solenoids with built-in voltage transient suppression diodes are recommended whenever possible.
Refer to the illustration for proper installation of diodes when built-in voltage transient suppression is not
available.
Locate inductive devices as far as possible from the components of the electronic control system. When
using electric motors it may also be necessary to add isolation relays to eliminate voltage transients, noise
and prevent back feed.
Note
LOFA harness assemblies typically include all required engine control suppression devices.
Added equipment will require additional protection.
8 463-3000-02 Rev C.2 -15-April-2008

Welding on Equipment with Electronic Controls

Proper welding procedures are required to avoid damage to electronic controls, sensors, and associated
components. The component should be removed for welding if possible.
The following procedure must be followed if the component must be welded while installed on equipment
with electronic controls. This procedure will minimize the risk of component damage.
Warning
Do not ground the welder to electrical components such as the control ground or sensors.
Improper grounding can cause damage to electrical components
Clamp the ground cable from the welder to the component being welded. Place the clamp
as close as possible to the weld to reduce the possibility of damage.
1. Stop the engine. Turn the key switch to the OFF position.
2. Disconnect the negative battery cable from the battery.
3. Open any installed battery disconnect switch.
4. Unplug the control system if possible.
5. Connect the welding ground cable as close as possible to the area to be welded.
6. Protect the wiring harness from welding debris and spatter.
7. Use standard welding methods to weld the materials.
463-3000-02 Rev C.2 -15-April-2008 9

General Troubleshooting
For additional information, refer to engine manufacturer troubleshooting guide.
No response from starter motor

Possible Cause Possible Remedy
No battery voltage to starter Verify wiring and battery connection (power and ground)
Battery discharged Charge or replace battery, verify alternator charging
Tripped overcurrent protection Correct fault, replace or reset overcurrent protection
No signal from control system No power to control system (see Control System Troubleshooting below)
Defective starter solenoid Replace starter solenoid
Defective starter motor Replace starter motor
Engine will crank but not start

Engine not getting fuel Check fuel level, filter, fuel pump, verify no air in fuel lines
Fuel run/stop solenoid not See Fuel Solenoid Run/Stop Troubleshooting (below)
engaged
No preheat (cold condition) See Preheat Troubleshooting
Engine runs for 10 seconds and shuts down

Shutdown switch input active Verify shutdown source exists, correct condition or correct faulty circuit
Battery not charging Verify alternator charging (see Alternator not charging battery below)
Control board did not sense Engine started through alternate method (i.e., manual air start, push start,
start signal etc.)
Defective control system See Control Panel Troubleshooting (below)
Engine runs longer than 10 seconds and shuts down

Shutdown switch input active Correct engine fault, verify shutdown switch wiring
Circuit overload protection Correct overload, keep control system from overheating
tripped (over 185° F/85° C)
Voltage transients (spikes) Add suppressor diodes, protect from nearby lightening strikes, shield
induced spikes from other equipment, add electric motor control relay
Defective control system See Control System Troubleshooting (below)
Alternator not charging battery

Broken or slipping alternator Adjust or replace alternator drive belt
drive belt
Alternator not excited Verify excitation circuit connected, replace faulty regulator, add additional
excitation resistor
Alternator output not Install charge wire
connected
Alternator not grounded Clean or add ground connection
Alternator faulty Replace faulty alternator
10 463-3000-02 Rev C.2 -15-April-2008
Fuel Run/Stop Solenoid Troubleshooting

Engine does not stop immediately
Back feed from motor (i.e., Add relay or blocking diode
cooling fan)
Sticking solenoid linkage Repair or replace solenoid linkage
Fuel valve without check valve Install or repair check valve
Fuel run/stop solenoid does not engage

No power to solenoid Locate reason for lack of power and correct (Circuit overloaded? Failed
suppressor diode? Faulty wiring?)
No power to solenoid pull coil Correct faulty wiring, check pull control circuit (see Power Box
Troubleshooting below)
Incorrect linkage adjustment Adjust solenoid linkage
Faulty solenoid Replace solenoid
Failed suppressor diode Correct wiring (diode reversed?), replace suppressor diode
Optional e-stop engaged Disengage e-stop
Engine not getting fuel

Empty fuel tank Fuel engine
Clogged filter Replace filter
Air in fuel lines Bleed fuel lines
Low fuel pressure Replace faulty fuel pump and/or clogged filter
Faulty fuel pump Replace fuel pump, correct wiring fault (electric fuel pump)
Preheat Troubleshooting
Engine is hard to start in cold conditions
Start attempt before preheat Wait for preheat time to elapse, crank as soon as time elapses
complete
Incorrect preheat specification Correct control system configuration, install correct control system
Heater faulty Replace heater
Heater relay faulty Replace relay
Preheat control not functioning Correct wiring, correct control system configuration
Faulty control system See Control System Troubleshooting (below)
Engine produces excessive white smoke after starting

Afterglow not enabled Reconfigure control system
Heater faulty Replace heater
Heater relay faulty Replace relay
Preheat control not functioning Correct wiring, correct control system configuration
Faulty control system See Control System Troubleshooting (below)
463-3000-02 Rev C.2 -15-April-2007 11

Control System Troubleshooting

Control system does not perform self test
Faulty connection to battery Correct battery connections (see Battery Circuit Requirements above)
Control system performs normal self test, engine cranks, runs and shuts down
Only Battery LED illuminated Correct battery charge failure (see Battery not charging above)
Only Oil Pressure LED Correct low oil pressure condition or faulty switch, correct wiring fault
Illuminated
Only Temperature LED Correct overheating condition or faulty switch, correct wiring fault
Illuminated
Only Aux LED Illuminated Correct fault condition (i.e. v-belt, coolant level) or faulty switch, correct
wiring fault
All normally closed shutdowns Add suppressor diodes, protect from nearby lightening strikes, shield
illuminate for one second induced spikes from other equipment, add electric motor control relay
(control system reset)
Testing Shutdown Inputs

Shutdown switches signal a fault by ground contact in most systems. Shutdown operation can be verified by
grounding the shutdown inputs individually. It may be necessary to remove the wire from the shutdown
switch to perform this test.
Note
Some thermostat housings are composites and do not provide ground for the switch.
12 463-3000-02 Rev C.2 -15-April-2008

" Power Box Option

The Power Box is a solid state, high current control system for mechanically governed, industrial diesel
engines. In addition to allowing extended harnesses, the Power Box provides 3-wire fuel run/stop solenoid
control to protect the pull coil from overheating. Power Box technology typically controls the starter solenoid,
fuel run/stop solenoid and cold starting aid. All outputs are overload protected and the system is fused to
avoid damage in the event of excess current demand. An additional fuse protects the control circuitry.
Warning
The Power Box is reverse polarity protected but may be damaged by attempting to start the
engine with battery polarity reversed.
When the fuel solenoid input is enabled, the fuel run/stop solenoid pull coil is enabled for the first second. In
normal operation, all other Power Box outputs are active as long as their corresponding inputs are active.
Power Box Troubleshooting

One output never activates
Input not active See Control System Troubleshooting (above)
Output shorted Correct fault
Failed Power Box Replace Power Box/harness assembly
All outputs never activate

Blown fuse(s) Correct fault, replace fuse(s)
Fuel run/stop solenoid pull output remains active

Faulty wiring Correct wiring
Revision History
Initial Release.
Rev A – 22-May-2006. Corrected typographical errors.
Rev B – 26-Oct-2006. Add symbols to Indicators, corrected typographical errors.
Rev C – 8-Jan-2007. Updated schematics
Rev C.1 – 28-Feb-2007. Added part numbers.
463-3000-02 Rev C.2 -15-April-2008 13

14 463-3000-02 Rev C.2 -15-April-2008

Typical Schematics
The following pages show typical schematics.

Details vary from installation to installation.
See the specific schematics for installation for details.
Need MC704 GT Panel Drawing
463-3000-02 Rev C.2 -15-April-2008 15

THE INFORMATION CONTAINED IN THIS DRAWING IS CONFIDENTIAL AND THE SOLE PROPERTY OF LOFA INDUSTRIES INC. Reproduction or dissemination in whole or in part in any form or medium without express priorwritten permission of LOFA INDUSTRIES INC is prohibited.
Gt 14 Pos. Male
A 14 AWG Pink/Black
Accessory (15)
B 16 AWG White
Tachometer
C 16 AWG Green
D+ Alternator
D 16 AWG Blue
Temp Gauge
E 16 AWG Orange
Pressure Gauge
F 16 AWG Tan
Preheat Control
G 12 AWG Red
Battery+ (30)
H 14 AWG Purple
Solenoid
J 16 AWG Yellow/Black
Aux Switch 2
K 16 AWG Yellow
Aux Switch 1
L 16 AWG Yellow/Blue
Temp Switch
M 16 AWG Yellow/Orange
Pressure Switch
N
Ground
P 12 AWG Red/Black
Starter (50)
P1
12 AWG Red
16 AWG Black
8 AWG Red 8 AWG Red
16 AWG Red
16 AWG Black
CR1 30 50 D+ B+ W
BAT1 WK G WK G
30
85
86 SW1 SW2
87
Aux 1 Aux 2 31 MOT1 TAS1 PS1
87a ALT1
Shutdown Shutdown SOL3
Ground Temperature Oil Pressure
Power Indicator Only Shutdown
Solenoid Sender/Switch Sender/Switch
Relay 3 Wire Solenoid
Battery N./O. N./C.
Wiring Diagram
Preheat
Unit
Pull
Hold
Note: -WK = Switch

B+ R IG L B+ R
1 2 -G = Gauge
Tolerances .X .XX .XXX ANGº

Description: MC-536 Engine Generic Diagram With GT Male +/- .1 .02 .005 2º
Part Number:
Rev Drawn By: MThiam Date: Sheet 1 of 1 INDUSTRIES, INC.

MANUFACTURER OF QUALITY ENGINE COMPONENTS
250 Hembree Park Dr Ste 122 Roswell GA 30076 phone: 770-569-9828 fax: 770-569-9829 www.LOFA.net
16 463 -3000 -02 Rev - C.2 - 15-April 2008

Leece-Neville Alternator 8SC Series
12 Volt, 185 Amps 24 Volt, 100, 150 & 175 Amps
24 Volt, 100, 150 & 175 Amps
The 8SC series is ideally suited for applications with
extra heavy electrical loads and high charge at idle.
These alternators have integral charging systems for
heavy belt loads and extremely high electrical loads
on large diesel or gasoline engines.
Features & Benefits

Simplified wiring - insulated three wire system
Built-in “Load Dump” protected regulator with
solid state circuitry and external adjustment 8SC Series
Varnished stator 12 Volt, 185 Amps with trash screen
7/8” heavy-duty shaft
SAE double lug mount with adjustable steel
bushing and steel insert
Heavy-duty 5/16” output stud for superior
electrical connections
Special AC terminal for connection of tachometers
and other instruments. Also “R” terminal for
indicator lamp hook-up
Long life copper graphite brushes enclosed in
a dirt resistant chamber to extend brush life.
The dynamically balanced rotor and shaft
assembly utilizes a 25 mm ball bearing at the
drive end and a 20 mm roller bearing. Both have
grease reservoirs and protective seals to provide Applications
long life and smooth operations.
Off-Highway
Internal and external capacitors to suppress radio Agriculture
frequency interference Emergency Vehicles
12 volt units have a trash screen for protection Heavy Duty Trucks
against foreign particles Transit Buses
Dimensions
(dimensions in inches)
Specifications
12 VOLT 24 VOLT
Dual Foot Model No. 8SC2020Z 8SC2023Z 8SC3014U 8SC3015U 8SC3019U
J-180 Mount Sales No. 110-563 110-565 110-298 110-302 110-316
Output, Stabilized:
5000 RPM 185 185 100 100 100
2500 RPM 153 153 78 84 84
Temperature Range -40 C to 93 C -40 C to 93 C -40 C to 93 C -40 C to 93 C -40 C to 93 C
Rotation Direction Bi- Directional Bi- Directional Bi- Directional Bi- Directional Bi- Directional
Max. Speed RPM 8000 8000 8000 8000 8000
Excitation Type Self Self Ignition Ignition Ignition
Lamp Circuit - .25 Amps - - -
Ground Isolated Isolated Isolated Isolated Isolated
Regulator Set Point Voltage 14.2 14.0 28.0 28.0 28.0
Voltage Adjustment - - +-1.0v +-1.0v +-1.0v
Regulator Part # 8RL2104 8RL2105 8RL3022 8RL3021 8RL3021
Weight (lbs/Kg) 27.75/12.6 27.75/12.6 27.75/12.6 27.75/12.6 27.75/12.6
Terminal Size: B+ 5/16˝-24 5/16˝-24 M8-1.25 5/16˝-24 5/16˝-24
B- 1/4˝-28 1/4˝-28 M6-1.25 1/4˝-28 1/4˝-28
AC 10-24 10-24 10-24 10-24 10-24
“I” Lamp - 10-24 - - -
Ignition - - M5-.8 10-24 10-24
Notes: Lamp Driver
Wire Diagrams
8SC3017VA,
8SC3018VA &
8SC3110V
8SC2020Z, 8SC2023Z,
8SC3014U, 8SC3009ZA,
8SC3068V & 8SC3029Z
Note:
8SC2020Z & 8SC2023Z = Stator Terminal
8SC3029Z, 8SC3068V &
8SC3009ZA = Indicator Light Terminal
8SC3014U = D+ Terminal
8SC3029ZA = Has Stator Lead
Specifications
24 VOLT
Dual Foot Model No. 8SC3017VA 8SC3018VA 8SC3068V 8SC3110V 8SC3009ZA 8SC3029Z
J-180 Mount Sales No. 110-575 110-579 110-431 110-568 110-258 110-569
Output, Stabilized:
5000 RPM 150 150 150 150 175 175
2500 RPM 98 98 97 120 54 80
Temperature Range -40 C to 93 C -40 C to 93 C -40 C to 93 C -40 C to 93 C -40 C to 93 C -40 C to 93 C
Rotation Direction Bi- Directional Bi- Directional Bi- Directional Bi- Directional Bi- Directional Bi- Directional
Max. Speed RPM 8000 8000 8000 8000 8000 8000
Excitation Type Ignition Ignition Ignition Ignition Ignition Ignition
Lamp Circuit - - - - - -
Ground Isolated Isolated Isolated Isolated Isolated Isolated
Regulator Set Point Voltage 28.0 28.0 28.0 28.0 28.0 28.0
Voltage Adjustment +-1.0v +-1.0v +-1.0v +-1.0v +-1.0v +-1.0v
Regulator Part # 8RL3013 8RL3013 8RL3021 8RL3013 8RL3021 8RL3021
Weight (lbs/Kg) 27.75/12.6 27.75/12.6 27.75/12.6 27.75/12.6 27.75/12.6 27.75/12.6
Terminal Size: B+ 5/16˝-24 5/16˝-24 5/16˝-24 5/16˝-24 5/16˝-24 5/16˝-24
B- 1/4˝-28 1/4˝-28 1/4˝-28 1/4˝-28 1/4˝-28 1/4˝-28
AC 10-24 10-24 10-24 10-24 10-24 10-24
“I” Lamp - - - - - -
Ignition 10-24 10-24 10-24 10-24 10-24 10-24
Notes: Remote Sense Remote Sense Remote Sense
Batteryless Batteryless Batteryless
Product Performance Stabilized Performance @ 25˚
24 Volt, 150 Amps 8SC3017VA & 8SC3018VA 12 Volt, 185 Amps 8SC2020Z & 8SC2023Z
160 200
140 180
160
120
140
Current (A)
100
Current (A)
120
80
100
60 80
40 60
40
20
20
0
0 1000 2000 3000 4000 5000 6000 7000
0
Alternator RPM 0 1000 2000 3000 4000 5000 6000 7000
Alternator RPM
24 Volt, 150 Amps 8SC3068V 24 Volt, 100 Amps 8SC3014U

180 120
150 100
Current (A)
Current (A)
120 80
90 60
60 40
30 20
0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000
Alternator RPM Alternator RPM
24 Volt, 150 Amps 8SC3110V 24 Volt, 175 Amps 8SC3009Z

200 200
180 180
160 160
140 140
Current (A)
Current (A)
120 120
100 100
80 80
60 60
40 40
20 20
0 0
0 1000 2000 3000 4000 5000 6000 7000 0 1000 2000 3000 4000 5000 6000 7000
Alternator RPM Alternator RPM
MANUFACTURING & OE SALES

LEECE-NEVILLE HEAVY DUTY SYSTEMS
QS9000 Certified AFTERMARKET SALES LEECE-NEVILLE
7585 Empire Drive
400 Main Street www.prestolite.com Florence, KY 41042
Arcade, NY 14009 (800) 354-0560
(716) 492-1700 Fax: (800) 997-6202
Fax: (716) 492-1660
PP-1140, 9/01
Technical Service
Bulletin
Source: Leece-Neville Heavy Duty Systems Division - Arcade, NY USA
Date: March 25, 2008
Bulletin No: TSB-1031
Models: 8SC Series Batteryless Alternators
Subject: Batteryless Alternator System
One of the Batteryless alternator’s uses is to power a bus air conditioning system. The alternator gets its field current from the
vehicle primary electrical sytem. No batteries are needed in this circuit. It is recommended to operate it at 3500 RPM minimum.
Because this alternator was designed for the batteryless sytem, Leece-Neville technical services recommends NOT connecting it to
a battery. Connecting two alternators together is NOT recommended, due to the difficulty of the two alternators to share the load.
For further information regarding this system, or for information on other recommendations, please contact the technical service
representative in your area or call our technical service call center at the number listed below. Other technical bulletins, as well as
a technical region map, are available on our website at www.prestolite.com.
WIRINGWIRING
GENERIC DIAGRAM FOR BATTERYLESS
DIAGRAM SYSTEMS SYSTEMS
FOR BATTERYLESS
NEGATIVE GROUND CIRCUIT
PRIMARY ELECTRICAL
SYSTEM
- + Bus Loads
Bus
Battery
B
Bus
Alternator
Air Conditioning
Master On/ Off Switch. **
IGN. * Yellow (20V)

External Sense.
VOLTAGE 20,000uf
150,000uf
B Bus
ADJ. 80V DC
Capacitor Air Condition Loads
*
Purple (22-28V)
- External Sense.
AC
Bleed
Resistor
+ 100 OHM
A 50 W
Alternator disconnect switch is

* 8RL3013
required to shut off alternator when Regulator
system is not in operation. only
** Switch must be open when AC unit is turned off
and closed when AC unit is turned on.
RECOMMENDED MIN. WIRE SIZES
SYSTEM TOTAL LENGTH OF CHARGING A B

RATING CIRCUIT
65 A 12 FEET OR LESS #8 #16
12-20 FEET #6 #14
85A 15 FEET OR LESS #6 #16
15-20 FEET #4 #14
12-20 FEET #4 #14
160A 15-25 FEET #2 #14
Important: The information contained in this bulletin is intended for use by trained, professional technicians who have the proper
tools, equipment, and training to perform the required maintenance described above. This information is NOT intended for ‘do-it-
yourselfers’, and you should not assume that this information applies to your equipment. If you have any questions regarding this
information please visit our website at www.prestolite.com, or contact our technical service department at:
Leece-Neville Heavy Duty Systems

400 Main Street Phone/Fax: (866) 288-9853
Arcade, NY 14009 Page 1 webmail@prestolite.com
Technical Service
Bulletin
Source: Leece-Neville Heavy Duty Systems Division - Arcade, NY USA
Date: July 18, 2008
Models: All 8SC/ SCJ
Subject: K183103997S Overhaul Kit Procedure.
This procedure will show you how to install items supplied with K183103997S overhaul kit.
Use procedure TSB-1068 to properly disassemble and assemble the alternator.
Front bearing change: Remove washer and

felt seal from shaft.
Step 1: Remove steel washer and felt

seal from shaft. (Fig 1)
Step 2: Press rotor from front housing.

(Fig 2) Fig 1
Step 3: Remove spacer and three front

bearing retaining screws.
(Fig 3)
Step 4: Press front bearing and seals

from front housing. (Fig 4)
Fig 2
Remove Spacer
Remove three Fig 3

screws
Fig 4

400 Main Street Phone/Fax: (866) 288-9853
Arcade, NY 14009 Page 1 webmail@prestolite.com
Technical Service
Bulletin
Date: July 18, 2008
Step 5: Remove seal from front housing.

(Fig 5) Remove seal
Step 6: Remove seal from front bearing

retainer. (Fig 6)
Note: On opposite sides of the front housing

and bearing retainer are two holes. Insert a
punch into these holes and tap with a ham- Fig 5
mer to remove the seals.
Step 7: Insert front housing seal. (Fig 7) Remove seal
Step 8: Insert front bearing retainer seal.

(Fig 8)
Note: When installing seals, press on the

outer diameter. Failure to do this can cause
damage to the seals. Fig 6
Insert seal
Insert seal
Fig 7 Fig 8

7585 Empire Drive Phone/Fax: (866) 288-9853
Florence, KY 41042 Page 2 webmail@prestolite.com
Technical Service
Bulletin
Date: July 18, 2008
Step 9: Press bearing into front housing. (Fig 9) Press bearing

into housing
Note: When installing bearings, press on the
damage to the bearing.
Step 10: Install front bearing retainer. (Fig 10)

Step 11: While holding front bearing retainer in Fig 9
place, turn over housing. Apply blue
locktite to three mounting screws and
install into front housing. (Fig 11) Install bearing
retainer.
Step 12: With a grease needle, inject grease
between the seal and the bearing.
Note: Grease needle can be purchased at any

auto parts store.
Recommended grease: Fig 10
High temperature synthetic bearing grease.

Install
3 screws.
Apply grease between

bearing and seal. Fig 12
Torque screws
Fig 11
24-30 in-lbs.

Technical Service
Bulletin
Date: July 18, 2008
Step 13: Turn housing over and with the

grease needle inject grease between
the seal and the bearing. (Fig 13)
Step 14: Figure 14 and 15 shows the proper

amount of grease that needs to be
applied.
Apply grease between
Note: The grease added between the bearing and Fig 13
bearing and seal.
the seals adds an additional protective measure
in preventing dust from penetrating the bearing.
This grease provides no lubricating properties to
the front bearing. Grease applied.
Figure 16 shows you the proper arrangements of

components in the front housing.
Fig 14
Grease applied. Fig 15 Fig 16

Technical Service
Bulletin
Date: July 18, 2008
Slip ring/ rear bearing inner race change:

Inspect rotor and measure key items in Fig 17.
Dim B: Dim D:
1.247 .995
If Dim A or B is out of tolerance a new rotor will 1.242 .970
need to be purchased. Refer to SP-1017 to
determine correct replacement part number.
Dim A: Dim C:
.9845 1.0605
If Dim C or D is out of tolerance or excessive wear .9841 1.0616
is present then proceed with this procedure.
Fig 17
Note: Use caution not to damage field wires
during the following procedures.
Step 15:Unsolder field wires from slip ring.

(Fig 18)
Step 16: Remove slip ring from shaft. (Fig 19)

Note: Use caution not to damage end of shaft
during slip ring removal.
Unsolder
Step 17: Cut nylon spacer off shaft and discard. field wires Fig 18
(Fig 20)
Remove Remove
slip ring Fig 19
nylon spacer. Fig 20

Technical Service
Bulletin
Date: July 18, 2008
Fig 21
Step 18: Clamp on bearing separator and press
bearing inner race off shaft. (Fig 21)
Note: Use caution not to damage shaft or field

wires.
Step 19: Apply high temperature silicone sealant

on rotor. (Fig 22) Use caution not
to damage shaft.
Step 20:Place new nylon spacer on shaft.
(Fig 23)
Fig 22
Step 21: Press bearing inner race onto shaft.
(Fig 24)

during installation.
Apply high temperature

silicone sealant.
Fig 23 Fig 24
Place nylon spacer Press on bearing

onto shaft. inner race.

Technical Service
Bulletin
Date: July 18, 2008
Fig 25
Step 22:Insert field wires through slip ring.
(Fig 25)
Step 23: Press slip ring onto shaft. (Fig 26)

while performing Step 23 and press on slip
ring outer diameter to prevent damage.
Step 24: Wrap field wires around slip ring

posts and solder.
Fig 26
Recommended solder: SN15PB85
Figure 28 shows you the proper arrangements

of components in the rotor.
Fig 27
Wrap field wires around

Fig 28
slip ring posts and solder.

Technical Service
Bulletin
Date: July 18, 2008
Rear bearing change:
Step 25: Remove snap ring from rear housing.

(Fig 29)
Step 26: Press old seals and bearing from rear

housing. (Fig 30)
Remove bearing Fig 29
retainer.
Step 27: Pack new bearing and seal cavities with
grease. (Fig 31)
Recommended grease:
High temperature synthetic bearing grease.
Step 28: Press seal into real housing. (Fig 32)
Note: When installing seals, press on the

damage to the seals. Fig 30
Use caution not to contaminate grease.
Press in first
seal. Fig 32
Fig 31

Technical Service
Bulletin
Date: July 18, 2008
Step 29: Press bearing into rear housing.

(Fig 33)
Note: When installing bearings, press on the

damage to the bearing.
Step 30: Press seal into rear housing. (Fig 34) Press in rear bearing.
Fig 33
Step 31: Install snap ring into rear housing.
(Fig 35)
Figure 36 shows you the proper arrangements

of components in the rear housing.
Press in seal. Fig 34
Insert snap ring. Fig 35

Fig 36

Technical Service
Bulletin
Date: July 18, 2008
Installing rotor into front

housing:
Step 32: Press rotor into front housing. (Fig 37)
Note: When pressing rotor support front

housing as close to the bearing as possible to
prevent damage to the front housing. Fig 37
Use caution not to damage slip ring when

pressing rotor into front housing.
Step 33: Slide spacer onto shaft. (Fig 38)
Step 34: Slide felt and steel washer on shaft.

(Fig 39)
To assemble the alternator please refer to

TSB-1068. Fig 38
Fig 39


Tech
hnical speciffications: TM
M55 / T
TM65
Benefitts for Bus

s and Coa
ach Opera
ators
 Best effficiency
 Reliability & durability

y
 High co
ooling capacity
y
Benefitts for Bus

s Makers
 Lightwe
eight and comp
pact
 Balanc
ced 14 cylinders
s design
 Excelle
ent performance-cost ratio
Benefitts for A/C

C System Makers
 Perfectt compatibility
 Premiu
um quality product
 Valeo warranty
w and competitive pric
cing
ww
ww.Transarcticc.com
REV 0

Model TM55 TM65
Technology Heavy Duty Swash Plate Heavy Duty Swash Plate
Displacement 550 cm³ / rev 635 cm³ / rev
Number of cylinders 14 (7 double-headed pistons) 14 (7 double-headed pistons)
Revolution range 600 – 4000 rpm 600 – 4000 rpm
Direction of rotation Clockwise (viewed from clutch) Clockwise (viewed from clutch)
Refrigerant HFC-134a HFC-134a
Bore 38.5 mm 38.5 mm
Stroke 33.7 mm 38.9 mm
Lubrication system Gear pump Gear pump
Shaft seal Lip seal type Lip seal type
Oil ZXL100PG PAG OIL (1500 cm³) or POE option ZXL100PG PAG OIL (1500 cm³) or POE option
Weight 18.1 kg (w/o clutch) 18.1 kg (w/o clutch)
Dimensions 354 – 194 – 294 mm (w/ clutch) 354 – 194 – 294 mm (w/ clutch)
Mounting Direct (side or base) Direct (side or base)
www.Transarctic.com
REV 0

TECHN
NICAL DR
RAWINGS
PERFO
ORMANCE
E CURVES
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ww.Transarcticc.com
REV 0

OPERA
ATION MA
AP
MAGNE
ETIC CLU
UTCH VAR
RIATIONS
S
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ww.Transarcticc.com
REV 0
SERVICE MANUAL
Valeo TM55 & TM65 Compressors
Copyright © 2013 Valeo Japan Co, LTD. All rights reserved.
Automotive technology, naturally

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 the Valeo TM55 and available at the time of printing.
TM65 compressors for bus air conditioning. The right is reserved 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 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 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
Radial bearing 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.
Swash plate rotation results in a reciprocating
piston movement horizontal to the drive shaft.
The cylinders, which are arranged at 51.4° intervals
Thrust bearing around the drive shaft, are each divided into 2
chambers, providing 7 front and 7 rear bores.
As each piston performs suction and compression
Suction Suction at either end, the compressor operates as a 14
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 naked flame and inflammable 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 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.
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 refrigerant 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
the 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 sigh glasses to read oil level at
the opposite one.
CAUTION!
Be careful on 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!
Current The specified oil quantity differs, depending
Compressor is
Compressor
replaced on the type of air conditioner system. A
is kept
label describing the specified quantity is
Amount attached to the compressor. Additionally, all
Factory
oil
Amount Charging to remove of the oil cannot be removed when draining
recovered amount from new the compressor as some remains as an oil
charge
compressor film on the inside of the compressor and
1500 - the system components. Therefore, refer
1000 or Same as to the table at left when recharging the
(amount
more recovered compressor with oil. Excess oil adversely
1500 recovered)
affects the cooling capacity and the
Under compressor.
1000 500
1000
unit: cu in 6. Install the oil filler plug and tighten it to the

Current specified torque.
Compressor is
Compressor Specified torque: 15 - 18 N·m
replaced
is kept {1.5 - 1.8 kgf·m, 11 - 13 lbf·ft]
Amount
Factory
Amount Charging to remove CAUTION!
oil
recovered amount from new The oil filler plug O-ring must be replaced
charge
compressor with a new one.
61 or Same as 61 - (amount
more recovered recovered)
91.5 Replacement of components
Under 61 61 30.5 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.
{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}
8. 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: SM5565-13012.01EN
Published by: VALEO JAPAN CO, LTD.
Printed in Japan
Copyright 2013, VALEO JAPAN CO, LTD.
For any inquiry regarding the present service manual,

contact us at vc-oura-sales@valeo.com
Valeo TM55 & TM65 Compressors for Bus Air-Conditioning
Valeo TM55 Copyright

& TM65 2013,Benefits
VALEO JAPAN
CO, LTD.
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: vc-oura-sales@valeo.com Email: vc-changchun-sales@valeo.com Email: vc-angers-sales@valeo.com Email: vc-dallas-sales@valeo.com
Copyright 2013, Valeo Japan CO, LTD | All rights reserved.

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PARTS AND SERVICE MANUAL

x4 10 18 1 EACH ENG30015 ENGINE, DIESEL, CAT 1.5L, 3 CYL, MODIFIED

12, 13, 14 1/4-13UNC 80-85 FT-LB

DISASSEMBLE AND RELOCATE OEM AIR FILTER.

REUSE EXISTING OEM FASTENERS. x3 7

REUSE EXISTING OEM GEAR CLAMP.

x2 4 1) USE SERVICABLE THREADLOCKER ON ALL FASTENERS TO ENGINE COMPONENTS

19 6 EACH BTQ06100 BOLT, HEX, 3/8-16UNC, 1", 8. PLT

. James Stewart 3/26/2014 TITLE

18 1) USE SERVICABLE THREADLOCKER ON ALL FASTENERS TO ENGINE COMPONENTS

22 3 EACH WLP04000 WASHER, LOCK, 1/4", 5, PLT

. James Stewart 3/24/2014 TITLE

➌ The pointer will move clockwise or

of the gauge. fore cutting any holes! 5. Installation Instructions 1

knife, pliers, etc.

requre calibration of the pointer.

This can be done as show in Diagram E.

DQSX_]UdUb DQSX_]UdUb 7b_e^T

Product: Description Date

To Reduce or Eliminate Erratic Operation in Tachometers

1. Purchase diode #1N4005 from your local electronics store.

2. Cut both ends of the diode so each is approx. 3/ 4" long.

4. Crimp a butt-splice connector on the other end of the diode.

6. Connect 1/ 4" female spade connector used in step # 3 above to terminal

7. Connect a ground (-) wire to terminal # 3.

8. Connect a switched 12-volt power wire to terminal # 2.

9. Set switches for the appropriate number of cylinders.

THIS IS A NON-CONTROLLED DOCUMENT

The LOFA MC704 Series is a compact micro panel that

• Automatic shutdown bypass during starting

• Hour meter (on MC704HP)

• Microprocessor–based control designed with high power

• First-Fault Diagnostic (FFD) LED pinpoints initial failure

• Thru-panel or threaded inserts mounting

• Reverse polarity protection

• Heavy-duty IP64 key switch with booted key

• Key switch features mechanical lock-out to prevent re-start attempts

• 12” connection pigtail terminating at a Delphi GT connector

MC704 LCP Micro Panel Without Hour Meter

250 Hembree Park Drive, Suite 122

Advanced Engine Control Technology

• 2 Year Limited Warranty

Voltage - System Nominal 10-28 VDC

Reverse Polarity Protection Yes

Fuel Solenoid 20A

Advanced Engine Control Technology

AUX. SWITCH N.O.

SOLENOID GROUND N./O.

ENGINE AND USER SUPPLIED WIRING

REDUCING VOLTAGE SPIKES

31 DELCO ALTERNATOR KUBOTA ALTERNATOR

PHONE 770 569 9828 FAX 770 569 9829 www.LOFA.net

15 KEY SWITCH (RED)

POWER RELAY SOLENOID GROUND N./O.

REDUCING VOLTAGE SPIKES

PHONE 770 569 9828 FAX 770 569 9829 www.LOFA.net

AUX. SWITCH N.O.

POWER RELAY SOLENOID GROUND N./O.

REDUCING VOLTAGE SPIKES