With DA-V5 Compressor

Tools Required:
J 9625-A Pressure Test Plate
J 23500-01 Portable Charging Station
J 34492 Compressor Holding Fixture

^ Be sure the compressor. has no oil internally.

1. Install J 9625-A on the rear head of the compressor.

2. Install the center hose of the manifold gage set on J 23500-01 to a refrigerant drum standing in an upright position and open the valve on the drum.

3. Install the charging station high and low pressure lines to the corresponding fittings on J 9625-A using gage adapters or hoses equipped with valve depressors. The suction port (low side) of the compressor has a large internal opening. The discharge port (high side) has a smaller internal opening into the compressor

^ Open the low pressure control, high pressure control and the refrigerant control on the charging station to allow the refrigerant vapor to flow into the compressor.

Important
^ Check for leaks at the pressure relief valve (2), compressor front and rear head seals (37) (39), through bolt head gaskets (32) and compressor shaft seal (29).

^ After the leak check, shut off the low pressure control and the high pressure control on charging station.

^ If an external leak is present, perform the necessary correction and recheck for leaks.

^ Loosen the manifold gage hose connections to the gage adapters connected to the low and high sides and allow the vapor pressure to release from the compressor If valve depressor type hoses are used, loosen the hose connections at the gage manifold to release the vapor pressure from the compressor

^ Disconnect both gage adapters or hoses from J 9625-A.

^ Add 0.085 kg (3 oz.) new 525 viscosity refrigerant oil to the compressor assembly. Rotate the complete compressor assembly (not the shaft or drive plate hub) slowly several turns to distribute oil to all cylinder and piston areas.

^ Install the shaft nut (21) on the compressor shaft (38) if the pulley assembly and clutch plate and hub assembly are not installed.

^ Using a box-end wrench, or a socket and handle. rotate the compressor shaft (38) several turns to lubricate the pistons and cylinder walls.

^ Connect the charging station high-pressure line, or a high-pressure gage and gage adapter to J 9625-A high-side connector.

^ Attach an adapter or depressor-type hose to the suction or low-pressure port of J 9625-A to open the Schrader-type valve. Oil will drain out of the compressor suction port adapter if the compressor is p0sitioned with the suction port downward.

^ Attach the compressor to J 34992 fixture and mount the compressor in a vise so that the compressor will be in a horizontal position and the shaft (38) can be turned with a wrench.

^ Rotate the compressor shaft (38) or drive plate hub six to eight complete revolutions at a speed of approximately one revolution per second. A slower rotation can result in a lower pump-up pressure and disqualify a good pumping compressor

^ Observe the reading on the high-pressure gage at the completion of the tenth revolution of the compressor shaft (38). The pressure reading for a good pumping compressor should be 690 kPa (100 psi) or above. A pressure reading of less than 620 kPa (90 psi) would indicate one or more suction and/or discharge valves leaking, an internal leak, or an inoperative valve Disassemble the compressor and repair as necessary. Reassemble and repeat the pump-up test.

^ Following the pressure pump-up test, release the air pressure from the high side and remove the gage adapters and J 9625-A test plate.

^ Tilt the compressor to place the suction and discharge ports downward to allow oil to drain from the compressor

^ Allow a 10-minute drain period and then charge the compressor with the proper amount of oil. Pour the new 525 viscosity refrigerant oil into the suction port.

^ If further assembly or processing is required, install a shipping plate or test plate J 9625-A to protect the compressor from contamination.