Leak Test

Tools Required:
J 5420 Straight Adapter
J 9396 Compressor Holding Fixture
J 9459 90 Degree Adapter
J 9625-A Pressure Test Set with Schrader Valves

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

2. Attach a center hose of manifold gage set on to a charging station with a refrigerant drum standing in an upright position and open the valve on the drum.

3. Connect the charging station "high" and "low" pressure lines to the correct fittings on J 9625-A, using J 5420 (7/16-inch) gage adapters. Adapters are not necessary if the hoses are equipped with Schrader core depressors.

- Suction port of the compressor has a large internal opening. The discharge port has a small internal opening into the compressor.

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

5. With J 38505, check for leaks at the pressure relie valve, compressor shell to cylinder, compressor front head seal, rear head seal, oil charge port and the compressor shaft seal. After checking, shut off the "low" pressure control and the 'high pressure control on the charging station.

6. If an external leak is present, repair and recheck

7. Loosen the manifold gage hose connections to the gage adapters connected to the "low" and "high" sides and allow the vapor pressure release slowly from the compressor.

8. Disconnect both of the gage adapters or hoses from J 9625-A.

9. Rotate the complete compressor assembly (not the crankshaft or drive plate hub) end to end several turns to distribute the oil to the cylinder and piston areas.

10. Install the shaft nut on the compressor crankshaft if the drive plate and clutch assembly are not installed

11. Using a box-end wrench or socket and handle, rotate the compressor crankshaft several turns to ensure the piston assembly lubrication.

12. Connect the charging station "high" pressure line or a "high" pressure gage and J 5420 or J 9459 to the J 9625-A high side connector

13. Attach J 5420 or J 9459 to the suction or "low" pressure port on J 9625-A to open the Schrader-type valve to atmosphere.

- Gage adapters are not required to connect to the test plate if the hoses have built-in Schrader depressors.
- Oil will drain out of the compressor suction port adapter if the compressor is positioned with the suction port down.

14. Attach the comoressor to J 9396 and clamp the fixture in a vise so that the compressor can be manually turned with. a wrench.

15. Using a wrench, rotate the compressor crankshaft about 10 complete revolutions at a speed of about one revolution per second.

NOTICE: Turning the compressor at less than one revolution per second can result in a lower pump up pressure and disqualify a good pumping compressor.

16. Observe the reading on the "high" pressure gage at the completion of the tenth revolution of the compressor.

- The pressure reading for a good pumping compressor should be 430 kPa (60 psi) or above.
- A pressure reading of less than 342 kPa (50 psi) would indicate one or more suction and/or discharge valves are leaking, an internal leak, or an inoperative valve.
- Disassemble the compressor and repair the leak. Assemble and repeat the test. Externally leak test.

17. After testing, release the air pressure from the "high" side and remove J 5420 or J 9459 and J 9625-A

18. Remove the oil charge screw and drain the oil sump

19. Allow the compressor to drain for 10 minutes, then charge with the proper amount of oil. The new oil may be poured into the Suction port. Torque the charge screw to 20 N.m (15 ft.lbs.).

20. If more processing is required, install the shipping plate or J 9625-A to keep air, dirt and moisture out of the compressor until installed.