SERVICE MANUAL & PARTS LIST
Contents
1. 4 With the piston in its top dead center position adjust each cylinder flush with top of piston and torque cylinder screws to 150 160 inch Ibs Re torque second time 5 Stack the valve components in order as originally assembled 6 Install the cylinder head and head screws NOTE The exhaust ports in the cylinder heads have been marked by omitting the ends of two of the fins 7 Torque all head screws 150 160 inch Ibs 8 Turn the motor shaft by hand at this point to ensure that the rod assembly is not hitting the head NOTE If rod assembly does hit head loosen cylinders and re adjust 9 Replace the motor intake and crossover tube 10 Re torque head screws again after running for 10 minutes Replacing Aftercooler Housing Parts Reference Figure E Aftercooler Fan Replacement Tools 1 8 hex drive or Allen wrench 2 Phillips screwdriver 12 in or smaller crescent wrench and thread locking compound 1 With compressor chassis extracted remove the five aftercooler housing bolts from the top cover 2 Lift aftercooler housing and disconnect the fan plug Figure E Aftercooler Removal Fan Plug Aftercooler Bolts 4 SE Aftercooler Housing Screws 5 Push In Elbow Fitting Straight Push In Fitting 4 Release Rings Remove media guard and media from the fan guard assembly 4 Remove the four aftercooler fan bolts gt Replace aftercooler fan and reassemble by reversing steps Secure a2. Tighten couplings retape Water collected in air storage tank Blow off tank Page 3 Page 4 Motor won t start with gauge pressure at 0 psi The thermal protection of the compressor may have been activated If system fans are still functioning allow the unit to cool briefly and restart If system fans are not running a high amperage condition existed resulting in the system circuit breaker being tripped This condition will result from a leaking check valve or malfunctioning unloader valve Motor experiences labored start with gauge pressure below 70 psi This condition results from the motor attempting to restart with pressure in the cylinder This is an indication of a leaking check valve or malfunctioning unloader valve Inspect the check valve and the unloader switch Service components as required Motor starts at an intermediate pressure or Pressure relief valve is activated Disconnect the unit from the power source Inspect the pressure switch for excessive wear and damaged or dirty components Replace parts as required Compressor cycles more frequently than is common Shut off compressor Watch the tank pressure gauge If the tank pressure drops rapidly check tubing and fittings for leaks If tubing and fittings are satisfactorily connected the check valve should be inspected for dirt and damage If after shut off tank pressure is maintained the tank should be blown off Water vapor can condense in the tank and reduce its capac
3. 4 Aftercooler Assembly 330257 1 o Aftercooler Cover Plate 460793 08 1 SCREW Socket head Stnl Commercial 1 1 4 20 x 3 4 O FITTING Brass Push In Elbow 730359 1 1 2 Tube x 1 4 MPT Viton type 11 FITTING Brass Push In Straight 730361 1 1 2 Tube x 1 4 MPT Viton type TUBING Air brake 1 2 in 730256 18 5 in 13 WASHER int star 10 stnl Commercial 3 Figure 8 Intake Fan Figure 9 Aftercooler Page 21 Reference Figure 10 ITEM PART NUMBER QUANTITY Motor Exhaust Chassis 330258 1 BOLT Socket head Commercial 1 Stnl 1 4 20 x 1 1 4 NUT Nyloc Stnl 1 4 20 Commercial 1 Motor Wire Set 875011 1 6 Motor Exhaust Strain Relief 840014 1 Strain Relief Nut 840015 1 Wire Clamp Steel Plated 510409 1 8 NUT Nyloc Stnl 8 32 Commercial 1 Reference Figure 11 ITEM PART NUMBER QUANTITY Electronics Module 330253 1 SCREWS Button head socket Commercial 2 Stnl 10 32 x 3 8 9 WASHER 6 Star Stnl 510419 1 NUT Nylok Stnl 6 32 Commercial 1 6 WASHER int star 10 stnl Commercial 2 Reference Figure 12 ITEM PART NUMBER QUANTITY Pressure Switch 4 Port Unloader 830052 1 7 8 Chrome Snapcap Hole Plug 510210 1 9 5 8 Grommet 870232 1 4 0 160 Pressure Gauge 1 4 MPT 730136 1 6 FITTING Quick disconnect AA 63 1 3 8 Female x 1 4 MPT w shut off O FITTING 730097 1 1 4 x 1 4 MPT Coupler Stnl saf
4. 60116 1 NUT Nyloc Stnl 8 32 Commercial 4 Handle 850041 2 D Exhaust Baffle 460771 08 1 SCREW Button head socket Commercial 10 Stnl 10 32 x 3 8 WASHER int star 10 stnl Commercial 4 O Weather Stripping 730394 62 in Figure 13A Top Cover Page 25 Page 26 Expendables ITEM PART NUMBER Felt Filter Media 730382 Compressor Rebuild Kit 730383 O Aftercooler Fan Filter Media 730380 730381 O Intake Fan Filter Media Notes Page 27 For Further Service And Or Technical Assistance Contact OAseptico PO Box 1548 Woodinville WA 98072 1548 1 800 426 5913 425 487 3157 Fax 425 487 2608 KE A 12 9 Printed In The USA email info aseptico com Internet www aseptico com 198 P N 420225
5. 60747 08 3 D Chassis Side Angle 460748 08 1 Chassis Cover Channel Front 460787 08 1 12 Chassis Cover Channel Left 460788 08 1 13 Chassis Cover Channel Back 460789 08 1 Chassis Cover Channel Right 460770 08 1 O SCREW Button head socket Commercial 24 Stnl 10 32 x 3 8 16 SCREW Button head socket Commercial 16 8 32 x 3 8 17 WASHER int star 10 stnl Commercial 24 18 WASHER int star 8 stnl Commercial 16 Reference Figure 5 ITEM PART NUMBER QUANTITY Air Storage Tank 330254 08 1 O Check Valve 730332 1 FITTING Brass Push In Elbow 730359 1 1 2 Tube x 1 4 MPT Viton type O FITTING Brass 730117 2 1 4 Poly x 1 8 MPT TUBING Air Brake 1 4 730130 12 5 in SCREW Button head socket Commercial 3 Stnl 10 32 x 3 8 WASHER int star 10 stnl Commercial 3 Figure 4 Compressor Chassis Figure 5 Air Storage Tank Page 17 Reference Figure 6 ITEM PART NUMBER QUANTITY Transformer Assembly 875013 1 Transformer Bracket 460818 04 2 BOLT Pan head Phillips Commercial 4 Stnl 10 32 x 2 NUT Nylok Stnl 10 32 Commercial 4 SCREW Button head socket Commercial 4 Stnl 10 32 x 3 8 WASHER nylon 0 062 thk 510019 2 WASHER int star 10 stnl Commercial 6 Reference Figure 7 ITEM PART NUMBER QUANTITY Compressor 720015 1 Motor Intake 460784 08 1 9 Crossover Tube 460777 08 1 FITTING A B branc
6. Removing the Air Storage Tank Reference Figure G 1 Remove compressor chassis from case bottom as per the Compressor Chassis Removal section 2 Complete Pressure Switch Replacement procedure omitting steps 7 9 and 10 3 Complete Check Valve Replacement procedure omitting steps 4 and 6 4 Remove three tank assembly screws and the 1 8 tube fitting on the tank bottom 5 Rotate the air storage tank slowly clockwise and remove through the exhaust duct side of the compressor chassis leading with the tank bottom Page 10 Figure F Pressure Switch Leads Peak Pressure Adjustment Compressor Cut In Cut Off __ Pressure Differential Adjustment Unloader Valve Nut Motor Wire Connections Figure G Star Washer Tank Removal Tank Assembly Screws Check Valve Replacing Pneumatic Tubing 1 Loosen tube at both ends by depressing the push in fitting release ring then the tube free or by removing the fitting nut 2 Note the ferrule type on both ends of the tube then discard tube section and attached ferrules 3 Select the correct tubing size and cut to the appropriate length Motor Aftercooler tube 13 0 in Tank Aftercooler tube 8 1 in Unloader tube 10 0 in Case side tank drain tube 15 0 in Tank side tank drain tube 24 0 in Case drain tube 15 5 in 4 Slide the fitting nut and the appropriate new ferrule onto the tube and re attach When replacing tubing routed to the aftercooler make aftercoole
7. SERVICE MANUAL amp PARTS LIST AA 75CE NSN 6520 01 456 7170 Part 2 of 2 OAseptico PO Box 1548 Woodinville WA 98072 1548 1 800 426 5913 425 487 3157 Fax 425 487 2608 email info aseptico com Internet www aseptico com TABLE OF CONTENTS Maintenance and Servicing Instructions Cleaning and Lubrication Performance Verification Inspection Troubleshooting Disassembly Repair Replacement Reassembly and Check Out Compressor Chassis Removal Compressor Removal Compressor Motor Service Kit Installation Aftercooler Fan Replacement Aftercooler Assembly Replacement Pressure Switch Replacement Check Valve Replacement Removing the Air Storage Tank Replacing Pneumatic Tubing Removing Electronics Module Removing the Intake Fan Transformer Replacement Parts List Case Base Case Top Inside Case Top Outside Compressor Chassis Air Storage Tank Transformer Compressor Intake Fan Aftercooler Motor Exhaust Electronics Module Pressure Switch Page 2 Table of Illustrations Figure A AA 75CF Component Identification Figure B Compressor Chassis Removal 5 Figure Group C Compressor Removal 6 Figure D Service Kit Installation 7 Figure E Aftercooler Removal 9 Figure F Pressure Switch Leads 11 Figure G Tank Removal 11 Figure H Intake Fan R
8. TCH UNLOADER VALVE AF TERCOOLER O COMPRESSOR AIR STORAGE TANK TANK DRAIN Page 13 PARTS LIST Reference Figure 1 ITEM PART NUMBER QUANTITY O Case Mil Spec Bottom 410128 1 Identification Plate Case 420229 1 Weather stripping 730375 63in Case Bumper 730109 4 o SCREW Hex head Stnl Commercial 4 1 4 20 x 1 1 4 Reference Figures 2 amp 3 ITEM PART NUMBER QUANTITY Case Mil Spec Top 410128 1 Case Leg 460776 08 2 Case Leg Pivot 460802 08 4 Case Leg Bumper 460828 4 o NUT Nylok Stnl 10 32 Commercial 4 230V Power cord 840007 1 120V Power cord 840049 1 O Cord Pouch 460649 08 1 BOLT Button head socket Commercial 4 Stnl 10 32 x 5 8 Washer Sealing Stnl 10 510353 4 Page 14 Figure 1 Case Base Figure 2 Case Top Inside Figure 3 Case Top Outside Page 15 Page 16 Reference Figure 4 ITEM PART NUMBER QUANTITY Chassis Base 330260 1 Vibration Isolator 730314 3 SCREW Flathead Phillips Commercial 6 Stnl 1 4 20 x 1 2 Chassis Corner Bracket 330261 4 Motor Mount 330255 08 1 O NUT Serrated flange Stnl 5 16 18 Commercial 4 7 WASHER Mil Spec 15795 812 Commercial 4 o BOLT Hex head Stnl 5 16 18 x 2 Commercial 4 Chassis Corner Angle 4
9. d pressure gauge 8 Using the hex of the coupler fitting turn pressure switch off of the air storage tank Guide wires slowly through the 5 8 grommet during the initial turn 9 Remove the coupler fitting from the pressure switch 10 Replace pressure switch and reassemble by reversing steps Use Teflon tape to seal pipe threaded fittings Note In addition to exposing wire connections removing the pressure switch cover exposes a pair of adjustment screws used to control the AA 75 CF compressor s cut off pressure and pressure range By turning the metal screw clockwise the air storage tank cut off pressure is increased Turning the plastic screw clockwise increases the separation between the cut off and cut in pressure Air storage tank pressure should never be adjusted to exceed 110 psi Check Valve Replacement Reference Figure G Tools 12 in or smaller crescent wrench Teflon tape or thread sealing compound 1 Remove compressor chassis from case bottom as per the Compressor Chassis Removal section 2 Loosen nuts on 1 8 poly fittings and disconnect unloader tube and tank side tank drain tube 3 Push in the release ring of the push in elbow fitting on the tank then pull tank aftercooler tube loose 4 Remove push in elbow fitting and 1 8 tube fitting from the check valve 5 Remove check valve from the air storage tank 6 Replace check valve and reassemble by reversing steps Use Teflon tape to seal pipe threaded fittings
10. ead screwdriver 12 in or smaller crescent wrench pliers and 1 4 open face wrench 1 Disconnect the compressor from the electrical power CAUTION You must disconnect the pump from electrical power before servicing it Failure to do so can result in severe personal injury or death 2 Drain the air storage tank and turn the pressure switch to the OFF position CAUTION You must vent all air lines to the compressor to remove pressure before servicing Failure to do so can result in severe personal injury 3 Remove the unit from the case bottom and the compressor from the compressor chassis as described in the Compressor Chassis removal and Compressor Removal subsections above 4 Remove the motor intake and the crossover tube from the compressor 5 Remove the cylinder heads and valve components DO NOT re arrange or reorient the valve components 6 Remove the cylinder and rings Make sure all compressor parts are clean before reassembling DO NOT use any chlorinated solvents to clean valves or any liquids to flush units The stainless steel valves may be cleaned with water All parts except the valves can be cleaned with any industrial non flammable non toxic non petroleum based cleaning solvent Assembly 1 Install piston seals piston rings and rider ring on each piston 2 Locate ring joints approximately opposite each other 3 Finger tighten the cylinders to the bracket with the cylinder screws and washers
11. emoval 12 Figure I Electronics Module 12 Figure J AA 75CF System Wiring Schematic 13 Figure K AA 75CF System Pneumatic Schematic 13 Figure E Case Base u ee 15 Figure 2 Case Top Inside 15 Figure 3 Case Top Outside 15 Figure 4 Compressor Chassis 17 Figure 5 Air Storage Tank 17 Figure 6 Transformer 19 Figure 7 Compressor ae 19 Figure 8 Intake Fan dere gute aei eeren 21 Figure 9 Afterco0ler_ 21 Figure 10 Motor Exhaust Chassis 23 Figure 11 Electronics Module 23 Figure 12 Pressure Switch 23 Figure 13A amp B Top Cover 25 Maintenance and Servicing Instructions Cleaning and Lubrication Exposed surfaces of the AA 75CF should be disinfected with a commercial dental disinfectant Abrasive cleaning agents have the potential to damage surface finishes and should be avoided To minimize the risk of corrosion do not use chlorinated solvents to clean either the inside or the outside of the compressor valves the air storage tank or the aftercooler assembly Lubrication of AA 75CF compressor components is unnecessary The compressor uses sealed bearings and Teflon cylinder technology to eliminate the need for lubrication The cooling fans similarly use sealed bearings Performance verification To verify proper compress
12. ety Relief Valve 730196 1 WASHER 8 Ext Star Stn 510420 1 Refer to Figure F Page 11 Page 22 Figure 10 Motor Exhaust Duct Figure 11 Electronics Module Figure 12 Pressure Switch Page 23 Page 24 Reference Figures 13A amp 13B ITEM PART NUMBER QUANTITY Top Cover 460746 08 1 Case Drain Fitting 730337 1 9 Tubing Support Sleeve 730095 1 TUBING Air Brake 1 4 in 730130 54 in FITTING Needle Valve 730336 1 1 8 MPT x 1 4 Poly Angle 0 FITTING Bulkhead mount 730307 1 1 8 FPT x 10 32 FITTING 10 32 x 1 4 Poly 730377 1 o NUT Wing Brass 1 4 20 Commercial 1 STUD Brass 1 4 20 x 1 1 2 Commercial 1 NUT Jam Brass 1 4 20 Commercial 1 Duplex Outlet 840047 1 Outlet Cover 850039 1 O SCREW Pan head Phillips Commercial 2 Stnl 6 32 x 3 8 D 15A Circuit Breaker 830058 1 D 2A Circuit Breaker 830057 1 O Power Connection Chassis 460798 08 1 17 SCREW Flat head Phillips Commercial 2 Stnl 6 32 x 3 8 O SCREW Button head socket Commercial 2 Stnl 10 32 x 3 8 Leg Socket 460820 08 4 O SCREW Flat head Phillips Commercial 4 Stnl 10 32 x 3 8 Intake Hose Trim 730378 9 1 in 1 4 Grommet 870185 2 5 8 Grommet 870232 1 Inlet Wire Set 875010 1 25 Control Wire Set 875012 1 Wire Clamp Steel Plated 510409 3 Wire Clamp Nylon 510410 1 O Wire Clamp Self Adhering 8
13. ftercooler housing bolts with thread locking compound Aftercooler Assembly Replacement Reference Figure E Tools 1 8 and 3 16 hex drive or Allen wrench flathead screwdriver 12 in or smaller crescent wrench serviceable thread locking compound and Teflon tape 1 2 5 Remove compressor chassis from case bottom as per the Compressor Chassis Removal section Loosen the nut of the motor tee fitting which secures the motor aftercooler tube Remove the tubing from the motor tee fitting leaving the nut and ferrule on the tube Reference Figure Group C Depress the release ring on the aftercooler push in elbow then pull free the motor aftercooler tube previously loosened in step 2 Remove the tank aftercooler tube from the push in elbow fitting on the tank by depressing the release ring and pulling on the tube Note the tube routing Rotate the compressor chassis onto its left side motor exhaust side Depress the release ring on the push in straight fitting at aftercooler and pull tube straight out 6 T 8 Remove the five aftercooler housing screws disconnect fan plug and remove aftercooler housing Slide the aftercooler toward the compressor chassis front power inlet and remove Clamp aftercooler block in vise and remove push in fittings straight fitting first then elbow Remove aftercooler manifold block screw and aftercooler cover plate Minimize handling of the aftercooler to avoid cracking it Replace afterco
14. h tee 730358 1 1 2 tube x 1 4 MPT FITTING A B Male Elbow 730357 1 3 8 tube x 1 4 MPT O FITTING Plug 730098 2 1 4 MPT x 1 4 Hex countersink FITTING 45 deg 730200 2 1 4 Flare x 1 4 MPT HOSE CLAMP Marine grade 510416 4 7 16 25 32 Miniature width TUBING 1 2 I D x 0 063 wall AROA Lin BOLT Socket head Stnl Commercial 4 5 16 18 x 1 1 2 WASHER Mil Spec 15795 812 Commercial 4 NUT Nyloc Stnl 5 16 18 Commercial 4 WASHER int star 8 stnl 510420 1 Page 18 Figure 6 Transformer Figure 7 Compressor Page 19 Reference Figure 8 Page 20 ITEM PART NUMBER QUANTITY Intake Fan 330259 1 Intake Fan Gasket 460779 1 SCREW Button head socket Commercial 2 Stnl 10 32 x 5 8 O Intake Hose 730339 12 in HOSE CLAMP Marine Grade 510400 2 1 13 16 2 3 4 O Intake Fan Filter Assembly 730334 1 BOLT Flat head Phillips Commercial 4 Stnl 6 32 x 1 2 8 NUT Nyloc Stnl 6 32 Commercial 4 1 4 Grommet 870185 1 D WIRE NUT Blue Commercial 2 WASHER 10 Ext Star Stnl 510421 1 Reference Figure 9 ITEM PART NUMBER QUANTITY Aftercooler Housing 460749 08 1 SCREW Button head socket Commercial 5 Stnl 10 32 x 3 8 Aftercooler Fan 330264 1 Aftercooler Fan Filter Assembly 730333 1 o BOLT Flat head Phillips Stnl Commercial 4 6 32 x 2 1 4 NUT Nyloc Stnl 6 32 Commercial
15. ity Compressor takes longer to build tank pressure than is common Check system tubing and fittings for leaks Inspect compressor air intake filters Replace filter cartridge if required No power to duplex outlet Verify system is powered Reset duplex outlet circuit breaker Disassembly Repair Replacement Reassembly and Check Out The AA 75CF has been designed for minimal required maintenance Compressor service should be performed every two thousand hours and component service should be required only when compo nent damage occurs or service life is exceeded Modular construction makes component inspection and replacement simple Maintenance can be performed with only the following tools a 7 16 socket drive a set of English Hex wrenches a 12 in and an 8 in crescent wrench flathead and 2 Phillips screwdrivers and a 1 4 inch open face wrench For Reassembly Teflon tape or an equivalent thread sealant should be applied to all pneumatics fittings and a serviceable thread locking compound should be applied to all fasteners To check the success of any repair perform the procedure detailed in the Performance Verification section The first step in any major component replacement is the removal of the compressor chassis from the case bottom Compressor Chassis Removal Tools 7 16 in socket wrench and serviceable thread locking compound 1 Remove case top 2 Carefully place unit top cover down 3 Remove the case bumper screw
16. locations See figure C or Figure I System Wiring Diagram Note There are two possible terminal locations at 1 and 5 Either location is acceptable Motor Intake Tre Duct Clamp Location Motor Tee Fitting u Figure Group C Compressor Removal Exhaust Duct Ground Wire Location Under Capacitor Cover So Inline Connectors and Insulated Terminals Page 6 Figure D Service Kit Installation ITEM PART NUMBER Cylinder Head Included With Motor Head Gasket Service Kit 9 Outlet Valve Service Kit O Plate Valve 720015 6 Inlet Valve Service Kit Cylinder Gasket Service Kit Cylinder 720015 8 Piston Ring Service Kit 9 Piston Seal Service Kit O Piston Rod Assembly 720015 11 Rider Ring Service Kit 12 Motor Mount Bolt Nut Washer Commercial D Motor 720015 114 Motor Tee Fitting 730358 O Motor Intake Assembly 460784 08 16 Crossover Tube 460777 08 Motor Elbow Fitting 730357 Felt Service Kit D service Kit 730383 Denotes parts included in the Service Kit Page 8 Compressor Motor Service Kit Installation Reference Figure D Adapted from Gast Operation amp Maintenance Technical Manual The compressor motor service kit contains the following Head Gasket Valves Cylinder gasket Piston Rings Piston Seals Rider Ring and Felts Dis Assembly Tools 3 16 1 4 and 5 16 hex drive or Allen wrench flat h
17. n reduce compressor output and may affect service life Initial compressor inspection is recommended at 2 000 hours The wear of the rider ring is an indica tion of the general condition of the compressor rings To inspect the rider rings remove the compressor from the case as per Compressor Removal instructions then disassemble the compressor cylinder heads If the rider ring measures 0 055 in or less an overhaul should be performed by installing a Service Kit See the Compressor Motor Service Kit Installation subsection of the Disassembly Repair Replacement Reassembly and Check Out Section of this manual for detailed installation procedures Troubleshooting Symptom Problem Action System non operational Main breaker tripped Reset main breaker Pressure switch contacts corroded Replace switch Compressor motor not running Main breaker tripped Reset main breaker Thermal overload tripped Allow several minutes to cool and restart No duplex outlet power Circuit breaker tripped Reset duplex breaker Tank pressure exceeds 110 psi Pressure switch settings altered Readjust according to Pressure Switch Replacement section note Compressor attempts to restart under load Leaking or obstructed check valve Disassembly and clean or replace Misaligned unloader valve Tighten unloader valve screw and realign Extended compressor cycle time Air demand has been altered Readjust instruments Clogged intake filters Clean or replace Air line leaks
18. oler assembly and reassemble by reversing steps being careful to reroute tubing as noted during removal Seal threaded ends of aftercooler push in fittings with Teflon tape or sealing compound and secure aftercooler housing bolts and aftercooler cover plate bolt with a serviceable thread locking compound Page 9 Replacing Air Storage Tank Components Pressure Switch Replacement Reference Figure F Tools 1 8 hex drive or Allen wrench 2 Phillips screw driver 12 in or smaller crescent wrench thread seal ing compound or Teflon tape 1 Unplug the AA 75CF compressor and drain the air storage tank 2 Remove compressor chassis from case bottom as per the Compressor Chassis Removal section 3 Remove four exhaust baffle screws to allow access to the pressure switch screws 4 Loosen pressure switch cover screw and remove pressure switch cover 5 Loosen the unloader valve nut and remove unloader tube 6 Loosen screws on the pressure switch to release the motor power leads the control wire leads and the switch ground When replacing leads be sure the wire pair leading through the motor exhaust chassis to the motor connects to the MOTOR location on the pressure switch and that the wire pair from the control wire set contained in polyester braid connects to the LINE location of the pressure switch Similar wire colors should attach on the same side of the pressure switch 7 Remove pressure relief valve female quick connect fitting an
19. or function make sure the tank gauge pressure is at zero the tank drain valve is closed and the pressure switch is in the OFF position Plug the compressor into the power source Switch the pressure switch to the AUTO position The compressor should charge the air storage tank and the intake and aftercooler fans should run Confirm that compressor shut off occurs at approximately 105 psi Open the tank drain valve When gauge pressure in the tank drops below 70 psi the compressor should restart Allow the tank to drain until all significant water is removed Once the air exiting the tank is dry to the touch close the tank drain valve When compressor cuts off verify that the fans continue to run for approximately two minutes and that the tank pressure remains constant near 100 psi A 5 psi drop can be expected after cut off Listen for leaks at pneumatic system connections If leaks are indicated by pressure loss but are not audible check the seals with a soap test A water liquid detergent solution should be applied to the circum ference of the joint A leak at a seal will cause the solution to bubble Tighten the joint if necessary reapply Teflon tape until bubbles no longer appear Inspection The felt media of the air intake filters requires periodic inspection and replacement Initial inspec tion is recommended after 500 hours Afterwards a service duration should be determined based on the operating conditions Excessive felt contamination ca
20. r connections first Page 11 Removing the Electronics Module Reference Figure I Tools 1 8 hex drive or Allen wrench and serviceable thread locking compound 1 Remove compressor chassis from case bottom 2 Uncouple control wire set connector and motor wire set connector 3 Remove the two electronics mounting screws 4 Reattach by reversing steps Install fasteners using a serviceable thread locking compound Figure H Intake Fan Removal Wire Nuts one shown second opposite 180 deg Intake Pan Screws Figure I Electronics Module Motor Wire Set Connector Zo Transformer Wire A Set Connector Removing the Intake Fan Reference Figure H Tools 1 8 hex drive or Allen wrench flat head screwdriver side cutters and serviceable thread locking compound 1 2 O D I A LA d Remove compressor chassis as per the Compressor Chassis Removal section Remove the 9 perimeter screws of the top cover 3 Remove pneumatic tubing at tank elbow push in fitting motor tee fitting and tank drain poly fitting Lift off the top cover Remove the electrical cover on the fan motor to expose the electrical connections Remove the two wire nuts and pull the two wire pairs through the 1 4 grommet Remove the two intake fan screws located on the underside of the top cover Remove the fan motor being careful not to bend the impeller Replace intake fan and reattach by reversing steps Install fasteners u
21. s sealing washers and case bumpers Reference Figure B 4 Lift off case bottom Use a rocking motion to clear ID plate rivets 5 Replace by reversing steps Secure case bumper screws using thread locking compound Figure A AA 75CF Component Identification Exhaust Baffle Intake Fan Assembly Aftercooler Housing Assembly Air Storage Tank Assembly ee berr Compressor Transformer TT Electronics Module Figure B Compressor Chassis Removal Page 5 Compressor Removal Reference Figure Group C Tools 1 4 and 5 16 hex drive or Allen wrench flat head screwdriver 12 in or smaller crescent wrench pliers and 1 4 open face wrench 1 Remove compressor chassis from case bottom as per the Compressor Chassis Removal section 2 Loosen the duct clamp at on the motor side of the intake hose and remove the hose from the motor intake Loosen the nut on the motor tee fitting and remove the 1 2 tubing Disconnect the ground wire from under the capacitor cover Loosen the exhaust duct and twist it free from of the compressor Disconnect the five insulated terminals from the back of the compressor Disconnect the two inline connectors Place the compressor chassis on its right side motor intake down O GO I W Remove the four motor mount bolts 10 Lift the compressor chassis off of the free compressor 11 Repair and reassemble by reversing steps Replace motor connections in their original
22. sing a serviceable thread locking compound Strip wires 1 4 in and reconnect using wire nuts Connect one orange and one purple wire to each black fan lead Individual wire orientation is not critical Transformer Replacement Reference Figure I Tools 1 8 hex drive or Allen wrench and thread locking compound 1 Remove compressor chassis from case bottom 2 Uncouple the connector between the transformer and the electronics box 3 Remove the four transformer bracket screws 4 Replace and reassemble by reversing steps Apply thread locking compound to screws when installing Be sure star washers are replaced under the bolt heads contacting the brackets and between the brackets and the chassis base Note To check the success of any repair perform the procedure detailed in the Verification section Page 12 Set Connectors Control Wir E Elec Mounting Screws AA 75CE SYSTEM WIRING SCHEMATIC Figure J MOTOR O een ALL 18 AWG ze 7 Te use 9 9 press y SWITCH CONTROL MODULE Pesa WHT 16 AVG A a BLK 16 AVG BROWN 16 AVG BLK 16 AWG WHT 16 AVG BE VIOLET 18 AVG Oy ORANGE 18 AWG 5 GE 2 JE mik 120 220 240 V 50 60 Hz 3 2 2 INPUT amp ul x MIN 204 i al 8 3 6 VIDLET 18 AWG AN DRANGE 18 AWG H 5 Ja WHT 16 AVG U DUTPUT FREE GU O AA 75CF SYSTEM PNEUMATIC SCHEMATIC Figure K PRESSURE GAUGE FEMALE QUICK CONNECT SAFETY RELIEF VALVE PRESSURE SWI
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