Leak Testing
Tools Required:J 5420 Straight Fitting
J 9625-A Pressure Test Set with Schrader Valve
J 23500-01 Portable Charging Station
1. Install J 9625-A on the rear head of the compressor
2. Install the center hose of the manifold gage set on the charging station to a refrigerant drum standing in an upright position and an open valve on the drum.
3. Install the charging station high and low pressure lines to the corresponding fittings on J 9526-A using J 5420 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, the high-pressure control and the refrigerant control on the charging station to allow refrigerant vapor to flow into the compressor.
Important
^ Check for leaks at the pressure relief valve, compressor front and rear head seals, center cylinder seal, through bolt head gaskets and the compressor shaft seal. After checking, shut off the low pressure control and the high pressure control on the charging station.
^ 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 from the compressor.
4. Disconnect J 5420 from J 9625-A.
5. Rotate the compressor (not the crank shaft or drive plate hub) to distribute oil to the cylinder and pistons.
6. Install a shaft nut on the compressor crankshaft if the drive plate and clutch assembly are not installed.
7. With a box-end wrench, or a socket and handle, rotate the compressor crankshaft or clutch drive plate on the crankshaft to lubricate the piston assembly and cylinder wall.
8. Connect the J 23500-01 Portable Charging Station high pressure line or a high pressure gage and J 5420 gage adapter to the J 9625 test plate highside connector.
Important
- Oil will drain Out of the compressor suction port adapter if the compressor is placed with the suction port downward.
9. Attach the compressor to the J 25008-A holding fixture with metric mounting screws. Clamp the compressor holding fixture in a vise so that the compressor can be turned with a wrench.
10. With a wrench, rotate the compressor crankshaft or drive plate hub ten revolutions at a speed of one revolution per second.
^ Turning the compressor at less than one revolution per second can cause a lower pump-up pressure and disqualify a good pumping compressor
11. Watch the reading on the high-pressure gage at the completion of the tenth revolution.
- The reading for a good pumping compressor should be 344.75 kPa (50 psi).
- A reading of less than 310.275 kPa (45 psi) would indicate one or more suction and/or discharge valves are leaking, an internal leak and/or discharge valves leaking, an internal leak or an inoperative valve. Disassemble and check the compressor.
12. After completing the pressure pump-up test, release the air pressure from the high side and remove J 5420 gage adapter and J 9625 test plate.
13. Tilt the compressor to place the suction and discharge ports downward.
14. Drain oil from the compressor After 10 minutes, charge with the proper amount of oil. Pour the oil into the suction port.
^ If further assembly or processing is required, install a shipping plate or J 9625 to keep air, dirt and moisture out of the compressor unit it is installed.