Leak Testing (External and Internal)

Compressor Leak Testing Fixture:

Bench-Check Procedure

1. Install Test Plate J 9625-A on Rear Head of compressor.
2. Using J 38100-C Refrigerant Recovery System, attach center hose of manifold gage set on charging station to a refrigerant drum standing in an upright position.
3. Connect Charging Station high and low pressure lines to corresponding fittings on Test Plate J 9625-A, using J 5420 Gage Adapters if hoses are not equipped with valve depressors.
- Suction port (low-side) of compressor has large internal opening. Discharge port (hi-side) has smaller internal opening into compressor.

4. Open low-pressure control, high-pressure control and refrigerant control on Charging Station to allow refrigerant vapor to flow into compressor.
5. Using a leak Detector, check for leaks at Pressure Relief Valve, compressor shell to cylinder, compressor front head seal, and compressor Shaft Seal. After checking, shut off low pressure control and high pressure control on Charging Station.
6. If an external leak is present, perform the necessary corrective measures and recheck for leaks to make certain the leak has been corrected.
7. Recover the Refrigerant.
8. Disconnect both Gage Adapters J 5420 from the Test Plate J 9625-A.
9. Add 90 ml (3 oz.) new 525 viscosity refrigerant oil to the compressor assembly. Rotate the complete compressor assembly (not the crankshaft or drive plate hub) slowly several turns to distribute oil to all cylinder and piston areas.
10. Install a M9 x 1.25 threaded 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 or clutch drive plate on the crankshaft several turns to ensure piston assembly to cylinder wall lubrication.
12. Connect the Charging Station high pressure line or a high pressure gage and Gage Adapter J 5420 to the Test Plate J 9625-A high side connector.
13. Attach an Adapter J 5420 to the suction or low pressure port of the Test Plate J 9625-A to open the Schrader-type valve.
- Oil will drain out of the compressor suction port adapter if the compressor is positioned with the suction port downward.

14. Attach the compressor to the Holding Fixture J 25008-A using metric mounting screws. Clamp the compressor Holding Fixture in a vise so that the compressor can be manually turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft or drive plate hub ten (10) complete revolutions at a speed of approximately one-revolution per second.
- 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 HIGH pressure gage at the completion of the tenth (10th) revolution of the compressor. The pressure reading for a good pumping compressor should be 344.75 kPa (50 p.s.i.) or above. A pressure reading of less than 310.275 kPa (45 p.s.i.) would indicate one or more suction and/or discharge valves leaking, an internal leak or an inoperative valve. The refrigerant must be recovered. compressor disassembled and checked for cause of leak. Repair as needed, reassemble and repeat the pump-up test. Externally leak test.
17. When the pressure pump-up test is completed. recover refrigerant from the HIGH side and remove the Gage Adapters J 5420 and Test Plate J 9625-A.
18. On the HR100T/HR110-MD compressor, tilt the compressor so that the compressor suction and discharge ports are down. Drain the oil from the compressor.
19. Allow the compressor to drain for 10 minutes, then charge with the proper amount of oil. The oil may be poured into the suction port.
- If further assembly or processing is required, a shipping plate or Test Plate J 9625-A should be installed to keep out air, dirt and moisture until the compressor is installed.