Leak Testing (External)

Bench-Check Procedure

1. Install test plate J 39893 on rear head of compressor.

2. Using J 39500-GM Refrigerant Recovery System, attach center hose of manifold gage set on charging station to a refrigerant drum standing in an upright drum.

3. Connect charging station high and low pressure lines to corresponding fittings on test plate J 39893. Suction port (low-side) of compressor has large internal opening. Discharge port (high-side) has smaller internal opening into compressor and deeper recess.

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, rear head switch location, compressor front and rear head seals, center cylinder seal, through bolt head gaskets 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 hoses from the test plate J 39893.

9. Add 90 ml (3 oz.) new PAG lubricant 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 insure piston assembly to cylinder wall lubrication.

12. Using J 39500-GM Refrigerant Recovery System, connect J 9893 the charging station high-pressure line to the test plate high-side connector.

13. Using J 39500-GM Refrigerant Recovery System, connect the charging station low-pressure line to the low pressure port of the test plate J 39893. Oil will drain out of the compressor suction port if the compressor is positioned with the suction port downward.

14. Attach the compressor to the J 33026 holding fixture and mount the compressor in a vise so that the compressor will be in a horizontal position and the shaft can be turned with a wrench.

15. Using a wrench, rotate the compressor crankshaft or drive plate hub ten 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 revolution of the compressor. 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, and the refrigerant must be recovered and the 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 the refrigerant from the high-side and remove the test plate J 39893.

18. Tilt the compressor so that the compressor suction and discharge ports are down. Drain the PAG lubricant from the compressor.

19. Allow the compressor to drain for 10 minutes, then refill with the proper amount of PAG lubricant. The PAG lubricant may be poured into the suction port. If further assembly or processing is required, a shipping plate or test plate J 39893 should be installed to keep out air, dirt and moisture until the compressor is installed.