Control Switches; Compressor Leak Testing - GMC T Series 1994 Repair Manual

CONTROL SWITCHES

Figure 20
Remove or Disconnect
1. R e c o v e r the r e fr i g e r a n t .
2. D i s c o n n e c t th e e l e c t r i c a l c o n n e c t o r f ro m th e s w i t c h in
t h e r e a r h e a d o f c o m p r e s s o r .
3. R e m o v e th e s w i t c h r e ta in i n g r in g u s in g J 5 4 0 3 in te r n a l
s n a p rin g pliers.
4. R e m o v e the s w it c h fro m the c o m p r e s s o r.
5. R e m o v e o ld O - r i n g se al f ro m th e s w i t c h c a v i t y u s i n g
J 9 5 5 3 - 0 1 O - r i n g r e m o v a l tool.
I f e x i s t i n g c o n tr o l s w it c h is r e in s ta l le d in th e c o m p r e s s o r ,
a n e w O - r i n g se al m u s t be u s e d a n d p r e f e r a b l y a n e w r e t a i n e r
r in g s h o u l d a ls o b e u se d . A n e w s w it c h kit h a s the O - r i n g a n d
r e t a i n e r r i n g in c l u d e d .
Install or Connect
C h e c k s w it c h c a v i t y a n d O - r i n g g r o o v e in the r e a r h e a d
f o r dirt o r f o r e i g n m a t e r i a l a n d c le a n a s n e c e s s a r y . In stall
a n e w O - r i n g c o a t e d w i t h c le a n r e f r i g e r a n t oil in to
g r o o v e in s w i t c h cavity.
2
L u b r i c a t e th e c o n tr o l
.
r e f r i g e r a n t oil a n d c a r e f u ll y insert s w i t c h i n to s w it c h
c a v i t y until s w it c h b o t t o m s in cavity .
3. U s i n g J 9 5 3 3 - 1 s n a p rin g p lie r s in stall s w i t c h r e t a i n i n g
r i n g w ith h i g h p o in t o f c u r v e d si d e s a d j a c e n t to s w it c h
h o u s i n g . Be su r e r e ta in i n g r in g is p r o p e r l y s e a t e d in
s w i t c h c a v i t y r e ta in i n g g r o o v e . L e a k test a c c o r d i n g to
b e n c h test p r o c e d u r e .

COMPRESSOR LEAK TESTING

(EXTERNAL AND INTERNAL)
Bench-Check Procedure
1. I n sta ll test p la te J 3 9 8 9 3 o n r e a r h e a d o f c o m p r e s s o r .
2. U s i n g J 3 9 5 0 0 - G M R e f r i g e r a n t R e c o v e r y S y s t e m , a tt a c h
c e n t e r h o s e o f m a n i f o l d g a g e set o n c h a r g i n g s t a ti o n to a
r e f r i g e r a n t d r u m s t a n d i n g in a n u p r i g h t d r u m .
3. C o n n e c t c h a r g i n g s t a ti o n h i g h a n d l o w p r e s s u r e lin e s to
c o r r e s p o n d i n g f ittin g s on test p la te J 3 9 8 9 3 . S u c t i o n port
( l o w - s i d e ) o f c o m p r e s s o r h a s larg e in te rn a l o p e n i n g .
D i s c h a r g e p o rt ( h i g h - s i d e ) h a s s m a l l e r in te r n a l o p e n i n g
i n to c o m p r e s s o r a n d d e e p e r re c e s s .
4. O p e n lo w p r e s s u r e c o n tr o l , h i g h p r e s s u r e c o n tr o l a n d
r e f r i g e r a n t c o n tr o l o n
r e f r i g e r a n t v a p o r to H o w in to c o m p r e s s o r .
5. U s i n g a lea k d e te c t o r , c h e c k f o r l e a k s at p r e s s u r e r e l i e f
v a lv e , r e a r h e a d sw it c h lo c a t io n , c o m p r e s s o r fr o n t a n d
r e a r h e a d se a ls, c e n t e r c y l i n d e r seal, t h r o u g h bolt h e a d
g a s k e t s a n d c o m p r e s s o r sh a ft seal. A f t e r c h e c k i n g , sh u t
o f f lo w p r e s s u r e c o n tr o l a n d h i g h - p r e s s u r e c o n tr o l on
c h a r g i n g sta tio n.
s w it c h h o u s i n g w ith c le a n
c h a r g i n g sta tio n to a l l o w
6. If an e x te r n a l leak is p r e s e n t , p e r f o r m th e n e c e s s a r y
c o rre c ti v e m e a s u r e s a n d r e c h e c k fo r le a k s t o m a k e
c e rta in the leak h a s b e e n c o r r e c t e d .
7. R e c o v e r th e re fr i g e ra n t .
8. D is c o n n e c t b o th h o s e s f r o m th e test p la te J 3 9 8 9 3 .
9. A d d 9 0 ml (3 oz.) n e w P A G l u b r i c a n t to th e c o m p r e s s o r
a sse m b ly . R o ta te th e c o m p l e t e c o m p r e s s o r a s s e m b l y
(not the c r a n k s h a f t o r d r i v e p la te h u b ) s l o w l y s e v e ra l
tu rn s to d i s trib u te oil to all c y l i n d e r a n d p i s t o n a r e a s .
10. Install a M 9 x 1.25 t h r e a d e d n u t o n th e c o m p r e s s o r
c r a n k s h a f t if the d r i v e pla te a n d c lu t c h a s s e m b l y a r e not
installed.
11. U s in g a b o x - e n d w r e n c h o r s o c k e t a n d h a n d l e , r o t a t e the
c o m p r e s s o r c r a n k s h a f t o r c lu t c h d r i v e p la te o n the
c r a n k s h a f t se v e ra l tu r n s to i n s u r e p i s t o n a s s e m b l y to
c y li n d e r wall l u b r ic a tio n .
12. U s in g J 3 9 5 0 0 - G M R e f r i g e r a n t
c o n n e c t the c h a r g i n g s t a ti o n h i g h - p r e s s u r e line to the
h ig h - s id e p r e s s u r e p ort o f the test p la te J 3 9 8 9 3 .
13. U s in g J 3 9 5 0 0 - G M R e f r i g e r a n t
c o n n e c t the c h a r g i n g s t a ti o n l o w - p r e s s u r e line to th e lo w
p r e s s u r e port o f th e test p la te J 3 9 8 9 3 . O il will d r a in o u t
o f the c o m p r e s s o r s u c t io n p o rt if th e c o m p r e s s o r is
p o s i t io n e d w ith the s u c t io n p o rt d o w n w a r d .
14. A tt a c h the c o m p r e s s o r to th e J 3 3 0 2 6 h o l d i n g f i x tu re a n d
m o u n t the c o m p r e s s o r in a vise so th at th e c o m p r e s s o r
will be in a h o r i z o n t a l p o s i t io n a n d th e s h a ft c a n be
tu r n e d w ith a w r e n c h .
15. U s in g a w r e n c h , r o ta te the c o m p r e s s o r c r a n k s h a f t o r
d r iv e plate h u b ten c o m p l e t e r e v o l u t i o n s at a s p e e d o f
a p p r o x i m a t e l y o n e - r e v o l u t i o n p e r s e c o n d . T u r n i n g the
c o m p r e s s o r at less t h a n o n e - r e v o l u t i o n p e r s e c o n d c a n
result in a lo w e r p u m p - u p p r e s s u r e a n d d i s q u a l i f y a g o o d
p u m p i n g c o m p r e s s o r .
16. O b s e r v e the r e a d i n g o n
c o m p l e t i o n o f th e te n t h r e v o l u t i o n o f th e c o m p r e s s o r .
T h e p re s s u re r e a d i n g f o r a g o o d p u m p i n g c o m p r e s s o r
s h o u l d be 6 9 0 k P a ( 1 0 0 psi) o r a b o v e . A p r e s s u r e r e a d i n g
o f less than 6 2 0 k P a ( 9 0 psi) w o u l d i n d ic a te o n e o r m o r e
s u c tio n a n d /o r d i s c h a r g e v a l v e s l e a k i n g a n i n te r n a l leak,
o r an in o p e r a ti v e v a lv e , a n d t h e r e f r i g e r a n t m u s t b e
r e c o v e r e d a n d th e c o m p r e s s o r
c h e c k e d fo r c a u s e o f leak . R e p a i r a s n e e d e d , r e a s s e m b l e
a n d re p e a t the p u m p - u p test. E x t e r n a l l y lea k test.
17. W h e n the p r e s s u r e p u m p - u p tes t is c o m p l e t e d , r e c o v e r
the re fr ig e ra n t f r o m the h i g h - s i d e a n d r e m o v e th e test
plate J 3 9 8 9 3 .
18. Tilt the c o m p r e s s o r so that th e c o m p r e s s o r s u c t io n a n d
d i s c h a r g e po rts are d o w n . D r a i n th e P A G l u b r ic a n t f r o m
the c o m p re s s o r.
19. A l l o w the c o m p r e s s o r to d r a in f o r 10 m i n u t e s , t h e n refill
w ith the p r o p e r a m o u n t o f P A G l u b r ic a n t , p e r oil b a la n c e
p r o c e d u r e in s e c tio n 1 B o f th e s e r v i c e m a n u a l . T h e P A G
lu b ric an t m a y be p o u r e d in to th e s u c t io n p ort. If f u r t h e r
a s s e m b l y or p r o c e s s i n g is r e q u i r e d , a s h i p p i n g p la te o r
test plate J 3 9 8 9 3 s h o u l d be i n s t a l l e d to k e e p out air, dirt
a n d m o is tu r e until the c o m p r e s s o r is in stalled .
R e c o v e r y S y s t e m ,
R e c o v e r y S y s t e m ,
h i g h - p r e s s u r e g a g e at th e
d i s a s s e m b l e d a n d