Aseptico Transport III Troubleshooting guide

AEU-525CF
AEU-525CFH
AEU-525CFH-14
Portable Dental System
SERVICE MANUAL
& PARTS LIST
Transport III

CONTENTS Page
General Service Information . . . . . . . . . . . . . . . . . . . . . . . . . .1
Inspection & Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Cleaning & Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ESD Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DISASSEMBLY
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INLET/OUTLET AIR FILTER ASSEMBLY . . . . . . . . . . . . . . . .4
WASTE TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WATER BOTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FOOT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
VACUUM VALVES & HOSES . . . . . . . . . . . . . . . . . . . . . . . . .5
ELECTRIC MOTOR & CORD ASSEMBLY . . . . . . . . . . . . . . .5
AIR/ELECTRIC MODULE ASSEMBLY . . . . . . . . . . . . . . . . . .5
HANDPIECE TUBING GUARD . . . . . . . . . . . . . . . . . . . . . . . .5
INSTRUMENT HOLDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
WATER FILTER & LUER FITTING . . . . . . . . . . . . . . . . . . . . .6
WATER CAP GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
WATER CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRIC MOTOR CONTROL PANEL HOUSING . . . . . . . .6
REAR WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
RIGHT SIDE WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
POWER BOARD AND INSULATORS . . . . . . . . . . . . . . . . . . .7
MANIFOLD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SCALER-ADJUSTMENT POTENTIOMETER . . . . . . . . . . . . .8
MANIFOLD BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SCALER CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . .10
THREE-WAY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
ELECTRIC MOTOR RECEPTACLE . . . . . . . . . . . . . . . . . . .11
SYRINGE AND SYRINGE TUBING . . . . . . . . . . . . . . . . . . . .11
SCALER WAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
FOOTSWITCH CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . .12
AIR/ELECTRIC MODULE LOCK-KNOB & HANDLE . . . . . .12
AIR BOTTLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .12
DIVIDER WALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
COMPRESSOR ASSEMBLY TOP PANEL . . . . . . . . . . . . . .13
VACUUM HOSE FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . .13
BULKHEAD TUBES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
MOTOR HOUSING COVER . . . . . . . . . . . . . . . . . . . . . . . . .14
ELECTRICAL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
48V POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
24V POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
DISPLAY MODULE POWER CABLE . . . . . . . . . . . . . . . . . .15
STALL SENSING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . .15
CONTROL BOARD PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
WASTE CONNECTOR CABLE ASSEMBLY . . . . . . . . . . . . .16
FAN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ELECTRICAL PANEL 10-POS TERMINAL BLOCK . . . . . . .16
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
CIRCUIT BREAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
POWER INLET LINE FILTER (EMI) . . . . . . . . . . . . . . . . . . .18
MOTOR HOUSING – LEFT WALL ASSEMBLY . . . . . . . . . .18
MOTOR HOUSING – RIGHT WALL ASSEMBLY . . . . . . . . .19
VENTURI & MUFFLER BRACKET ASSEMBLY . . . . . . . . . .20
COMPRESSOR/VACUUM PUMP ASSEMBLY . . . . . . . . . . .21
MOTOR MOUNT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .22
AIR-ELECTRIC BULKHEAD INSERT . . . . . . . . . . . . . . . . . .22
CASE & LID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
i
STERILIZATION & MAINTENANCE . . . . . . . . . . . . . . . . .24-25
TROUBLESHOOTING GUIDE . . . . . . . . . . . . . . . . . . . . . . . .26
REPLACEMENT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . .27
FINAL INSPECTION & TESTING . . . . . . . . . . . . . . . . . . .28-30
SYMBOL DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
REQUIRED TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . .32
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
TABLE OF CONTENTS
Page

instrument holders are air-activated holders. If the High
Vacuum Evacuator (HVE) or low-volume saliva ejector
instruments (Fig. 3)
are removed from
their holders or if
they aren't properly
seated in their
holders, the com-
pressor will run
continuously, even
when the system
pressure is fully
pressurized. If the
HVE and saliva ejector instruments are seated in their
holders properly but the compressor fails to turn off, turn the
unit's power switch OFF and check for air leaks in the
system. If the system pressure gauge is showing pressure,
the leaking sound should be detectable. Use your ear, or
place a tube to your ear like a stethoscope, to locate the
source of the leak. If a leak can't be heard from any air lines
or fittings, check the air and water bottles for tightness and
the condition of their seals, and check the three O-rings from
the junction block.
Air/Water Syringe
Check the 3-Way Air/Water Syringe (Fig. 4a) by depressing
the air and water syringe buttons individually then both
simultaneously for
air/water mist. This
mist can be
adjusted with the
two syringe flow
control knobs
located on the
manifold control
panel (see Fig. 4b).
The top knob adjusts the water flow and the bottom knob
adusts the air flow. Turn the knobs clockwise to decrease the
flow or counterclockwise to increase the flow.
Water Filter
Inspect the water filter (Fig. 5) on the
end of the water pick-up tube that
protrudes into the water supply bottle.
If the filter becomes clogged and
restricts the water flow, it needs to be
cleaned by reverse flushing, or
replaced. CAUTION: Do not run saline solutions through the
water system -- saline will rust the water filter.
Air Filters
The system
provides a dual
air filtration
system. The
primary filter
(Fig. 5a) is
installed into the
door frame on
the case lid and
is used in dusty
environments. It
uses a foam filter that can be detached and cleaned. Simply
pull the foam pad off the frame studs and clean with soap
GENERAL SERVICE INFORMATION
This service manual offers information not available in the
AEU-525CF/AEU-525CFH/AEU-525CFH-14 Transport III
Operation and Maintenance Instruction Manual. It will help
you better understand the operation of the Transport III
system, thereby reducing service time. A Replacement Parts
List is also included on page 27. See the Schematic Drawing
Set (PN 420991) for assembly drawings with individual part
numbers, plumbing diagrams, and electrical schematics.
The plumbing and electrical diagrams show all air, water,
and wiring components as installed in the unit.
INSPECTION & OPERATION VERIFICATION
To verify that the Transport III unit is functioning properly, first
follow the Setup procedure
in the Operation and
Maintenance Manual or in
the 525 Setup Video
presented on the Aseptico
website. The System is
designed to operate from
110V or 230V 50/60Hz
power. A manually operated
switch located next to the
power inlet cord, allows the user to select the proper voltage
(Fig. 1).
Turn both rocker switches on the motor housing to the ‘ON’
position. The left-hand switch turns the unit power On/Off.
The right-hand switch acts as a circuit breaker for the
compressor. Electrical overloads will trip both switches.
Simply turn the switches back On to reset. Green LED’s
adjacent to each switch illuminate when the switches are
On. NOTE: When the unit is in use, it’s compressor motor
will occasionally turn On and Off, to maintain proper
pressure. IMPORTANT: The switch should be left in the On
position when not in use.
Toggle the water-bottle purge
switch located on the back side of
the air/ electric module to the
“PRESSURE” position (Fig. 2a).
Turn the main power switch, to
the ON position. The compressor
pump should pressurize the air
and water bottles and maintain
the system operating pressure at
45-55 PSI (3.10-3.78 bar). Check
the pressure on the gauge
located on the side of the
air/electric module (Fig. 2b).
The Transport III System uses a single compressor motor
with a split head. The split head provides pressure on one
side and vacuum on the other. The vacuum side uses venturi
boosters to increase the vacuum. The system pressure is
regulated by a switch located on the right wall of the motor
housing assembly. This switch activates the compressor
when the pressure drops to approximately 45 PSI, and it
stops the compressor when the pressure builds to
approximately 50 PSI.
The electric motor/handpiece, scaler, and vacuum
1
VOLTAGE SELECTOR
SWITCH
POWER
ON/OFF COMPRESSOR
CIRCUIT
BREAKER
Figure 1
Figure 2a
Figure 2b
WATER BOTTLE
PURGE SWITCH
PRESSURE
GAUGE
HVE
ELECTRIC
HANDPIECE
SCALER SALIVA
EJECTOR
SYRINGE
Figure 3
Figure 4a Figure 4b
SYRINGE
AIR
ADJUST
AIR
WATER
SYRINGE
WATER
ADJUST
Figure 5
Filter
DETACHABLE
AIR FILTER
Figure 5a Figure 5b
COMPRESSOR
AIR FILTER

2
and water or compressed air. The secondary air filter is a
cannister-type filter that threads into the compressor head
(Fig. 5b). This filter should be replaced if it becomes clogged
and restricts air flow.
Vacuum System
To check the function of the
vacuum system, first allow the
system to reach full pressure.
Check that all four tubes to
the waste tank are fully
seated and locked into their
fittings on the top of the waste
tank (Fig. 6a). Ensure that the
waste tank level sensor is
plugged into the connector on
the unit’s compressor housing
(Fig. 6b). The system will not
activate the compressor if this
sensor is not connected
properly.
Fill a container with 300
milliliters of water. Turn the
valve on the low vacuum saliva ejector instrument to the
OFF position and submerge the HVE instrument into the
container. It should take less than 10 seconds to extract the
300 milliliters of water from the container using the HVE.
Refill the 300 milliliters of water and turn the HVE instrument
OFF and the saliva ejector to ON, then submerge the saliva
ejector instrument into the container. It should take less than
18 seconds to remove 300 milliliters of water using the saliva
ejector.
Instruments:
To check the functions of the electric motor/handpiece and
scaler, remove each instrument from its respective holder
one at a time (see Fig. 3), and test the instrument, with
coolant water and/or air flow. Both instruments are activated
by the foot control.
Electric Motor/Handpiece
Remove the electric motor/handpiece from its holder (Fig. 3).
A handpiece water ON/OFF toggle valve is located on the
manifold control
panel (Fig. 7).
Place this toggle in
the “ON” position
and depress the
foot pedal. Ensure
that coolant water
flows to the
handpiece. A water
flow adjustment
valve is also
provided to control
the volume of water
going to the hand-
piece. This valve is located next to the ON/OFF toggle valve
(Fig. 7). Turn this adjustment valve counterclock-wise to
increase flow, then clockwise to decrease flow.
A handpiece air ON/OFF toggle valve is also located on the
manifold control panel (see Fig. 7). This valve allows coolant
air to flow to the electric handpiece. Depress the foot pedal
and place this toggle in the “ON” position. Ensure that
coolant air flows to the handpiece. An air flow adjustment
valve is located next to this ON/OFF toggle valve (Fig. 7).
Turn this adjustment valve counterclockwise to increase the
volume of air to the handpiece, then turn it clockwise to
decrease the flow.
Return the electric handpiece to its holder when testing is
complete.
Scaler
Remove the Scaler from its holder (Fig. 3). A scaler water
ON/OFF toggle switch is located on the manifold control
panel, just below the ultrasonic adjustment knob (Fig. 8).
Place this toggle switch in the “ON” position and depress the
foot pedal. Ensure that coolant water flows to the scaler. A
water flow adjustment valve is also provided to control the
volume of water going to the scaler. This valve is located
next to the On/OFF toggle switch. Turn this adjustment valve
counterclockwise to increase coolant flow, then clockwise to
decrease coolant flow. During normal operation, adjust this
valve until the water flow is no less than 20 ml/min at the tip.
A scaler ultrasonic setting control switch is also located on
the manifold control panel (Fig. 8). This switch adjusts the
ultrasonic intensity
of the scaler. Turn
the control knob
clockwise to max-
imum intensity, then
counterclock-wise
to minimum. When
scaling, follow the
tip manufacturer's
recommended
ultrasonic settings
for each tip.
Return the scaler to its holder when testing is complete.
Cleaning and Lubrication:
When servicing the Transport III system, the parts of any
component disassembled should be thoroughly cleaned and
inspected before reassembly. A hot detergent solution is an
effective cleaner on all non-electrical parts. Flush all non-
electrical parts with clear, hot water. Abrasive cleaners have
the potential to damage surface finishes and should be
avoided. Any wiping should be done with a soft lint-free
cloth.
Electrical parts should be cleaned with an appropriate
electrical parts cleaner or air.
CAUTION: Use only NON-foaming cleansers in the vaccum
lines.
Use a silicone base lubricating grease, such as Parker
Super O-Lube, PN 490138, to lubricate O-rings and seals in
the system. Before performing any reassembly of parts that
contain O-rings or seals, apply a light coat of silicone grease.
This will make installation easier and prevent the O-rings or
seals from being damaged.
Figure 6a
LEVEL
SENSOR
CORD
SENSOR CORD
CONNECTOR
(Below Air Filter)
Figure 6b
WASTE
TANK
HANDPIECE AIR
ADJUSTMENT VALVE
HANDPIECE AIR
ON/OFF VALVE
HANDPIECE WATER
ADJUSTMENT VALVE
HANDPIECE WATER
ON/OFF VALVE
SCALER
ULTRASONIC
CONTROL SWITCH
SCALER
COOLANT FLOW
ADJUSTMENT SWITCH
SCALER
COOLANT
ON/OFF SWITCH
Figure 7
Figure 8

3
Water Lines
Disinfect the water lines weekly. Prepare a 1:10 bleach
solution (1 part household bleach to 9 parts water).
Remove water supply bottle and discard residual water.
Replace the empty water supply bottle and air purge all
waterlines. Fill water supply bottle with bleach solution.
Run bleach solution through all lines. Allow bleach solution
to stand in lines for 10 minutes. Remove water supply
bottle and discard bleach. Flush water supply bottle and all
lines thoroughly with clean water. Air purge and leave lines
dry until next clinical use.
REFER TO STERILIZATION AND MAINTENANCE SECTION ON PAGE
24 FOR MORE CLEANING INSTRUCTIONS.
Adhesives
Refer to included Schematic Drawing Set, PN 420991, for
proper identification and application of all adhesives.
ESD PRECAUTIONS
The following electrostatic controls must be used when
working on this unit:
ESD Training and Standards:
Employees handling electronic sub-assemblies and ESD
sensitive components are expected to be trained. Training
should be based on IPC-A-610 or equivalent ESD standard
ANSI/ESD-S-20-20 – Protection of Electrical and Electronic
Parts, Assemblies and Equipment.
ESD Static Controlled Area:
Areas that are designated for handling and working on
electronic sub-assemblies or their components should be
marked off with signs indicating the area where ESD controls
are to be enforced. These areas are to be kept clear from
persons that are not trained to prevent ESD damage from
occurring.
ESD Environment:
The work area is to be free of all static generating materials,
such as plastic containers, water bottles, plastic bags, plastic
objects, such as plastic pens, heat guns (unless made for the
ESD environment).
ESD Jackets:
Clothing should be non-static generating (cotton).
Static generating clothing (e.g. wool, acrylic, nylon) must be
covered with an ESD jacket that is buttoned closed.
Optional gloves:
Nitrile gloves may be used to cover the hands when working,
but are not required.
Seating:
ESD Chairs should be used in place of static generating
chairs (e.g. modern office seating use static generating
materials).
Storage and packaging:
All circuit boards and components are to be stored on or in
static dissipative or static shielding material, throughout
shipping and storage.
ESD Wrist Strap and Mat Routine Checks:
The wrist strap should be checked daily using an ESD wrist
strap testing station. See chart below.
ESD mats should be checked at least quarterly.
CAUTION:
Do not run saline solutions through the water
system -- saline will rust the water filters.

4
peel the large Outer Foam Pad (PN 730685), Inner Foam
Pad (PN 730684), or circular Tube Foam Pan (PN 730687)
off their Mounting Studs (PN 510848) and Velcro Strips (PN
480030) (Fig. 11). Clean or replace pads as needed and
then reattach to frame.
WASTE TANK ASSEMBLY
The Waste Tank is located on the back side of the Transport
III, hanging from a mounting bracket on the case lid (Fig. 12).
First, remove the four gray hoses from the top of the waste-
tank lid. Note the color match between the black and white
rotating latches on the
lid with their respective
black or white hose
fittings. Also note that
the HVE and saliva-
ejector instrument
hose fittings are keyed
to only fit their
respective inlet ports.
Unplug the waste level
sensor from its
connector on the
Electrical Panel
Assembly (see Fig. 9).
Ensure that the tank
has been cleaned of all waste and residue before removing
(refer to Operations Manual for instructions on emptying the
Waste Tank.) Lift Tank off mounting bracket and set aside for
reassembly later.
WATER BOTTLE
Release any residual pressure from the Transport III Water
Bottle by toggling the Pressure Release Valve to the right
(Fig. 13). Unscrew the Water Bottle from its cap and carefully
lower the bottle until clear of its water-supply tube/ filter
assembly. Place Bottle aside for reassembly later.
DISASSEMBLY
OVERVIEW: When disassembling the AEU-525CF
Transport III System, it is recommended that its modular
subassemblies be removed and disassembled in the order
shown below:
1. Inlet/Outlet Air Filter Assy
2. Waste Tank Assy (*)
3. Dental Instruments
4. Water Bottle
5. Air/Electric Module Assy (*)
6. Air Bottle Assy
7. Top Shelf Components
8. Electrical Panel Assy
9. Motor Housing - Left Wall Assy
10. Motor Housing - Right Wall Assy
11. Venturi & Muffler Bracket Assy
12. Compressor/Vacuum Pump Assy
13. Case Assy
(*) The Waste Tank and Air/Electric Manifold Block are not
customer-serviceable subassemblies and should not be
disassembled in the field -- please return these items to
Aseptico if repairs are necessary.
The operator control panels are located on the Air/Electric
Module Assembly. The power inlets and power supplies are
located on the Electrical Panel Assembly, and the
compressor and its vacuum components are located on the
Motor Housing Assembly.
INLET/OUTLET AIR FILTER ASSEMBLY
The socket for the Waste Tank Level Sensor Connector is
located on the Electrical Panel Assemby, behind the Air
Filter Assembly (see Fig. 9).
Grasp the locking collar on the Connector and pull the
Connector straight out of its socket, through the plastic hole
in the Air Filter Assembly. The Connector is keyed to the
socket, so when
reinstalling, press the
connector gently
against the socket
then rotate until the
connector aligns with
and enters the socket.
Ensure that the
connector is dry and
free of any moisture
before reconnecting to the socket.
Swing the Connector and cord out of the way. Use either a
standard flat-head screwdriver, or the fastener tool provided
on the inside of the Transport III case lid, to loosen the four
fasteners on the Filter frame (Fig. 10). Turn the fasteners
counter-clockwise 1/4-
turn. Lift the Filter out
of the lid door frame
and move to a
workbench for further
disassembly.
The three foam filter
pads can be detached
from the Filter frame
for cleaning or
replacement. Carefully
Figure 11 OUTER
FOAM
PAD
TUBE
FOAM PAD
WASTE
SENSOR
SOCKET
Figure 9
WASTE SENSOR
CONNECTOR
FILTER
FASTENERS (4)
Figure 10
KEYWAY
Figure 12 ROTATING
LATCH
INNER FOAM
PAD
VELCRO
MTG STUD (X10)
HVE
HOSE
SALIVA
EJECTOR
HOSE MOUNTING
BRACKET
Figure 13
WATER BOTTLE
CAP
PRESSURE
RELEASE
VALVE
(RELEASE)

5
FOOT CONTROL
The Transport III Foot Control connector is located on the
bottom of the Air/Electric Module Assembly (Fig. 14). Loosen
the outer sleeve on
the cord connector
and pull the
connector straight
out of its receptacle.
Place the Foot
Control aside for
reassembly later.
IMPORTANT: The
Foot Control is not a
customer service-
able item and should be replaced or returned to Aseptico for
repairs, if necessary.
VACUUM VALVES & HOSES
Remove the HVE and saliva ejector valves from their
respective holders and move to a work bench for inspection
and/or repair (Fig. 15):
• Inspect hoses for cracks or leaks - replace if necessary.
• Check the integrity of the HVE ‘O’ rings (PN 520101)
and the saliva ejector ‘O’ ring (PN 520100) - replace if
necessary.
• The anodized aluminum bodies of the HVE & saliva
ejector valves (PNs AA-35LAD & AA-37LAD) can be
snapped apart at their swivel connectors. The levers
and Viton® O-ring spools can be disassembled without
tools, for cleaning and lubrication. (Use small amount of
Parker Super O-Lube (PN 490138) to lubricate). Ensure
that the valve heads swivel freely and that the levers
turn On/Off properly - replace if necessary.
ELECTRIC MOTOR & CORD ASSEMBLY
Remove the Electric Handpiece/Motor from its holder.
Detach the
handpiece
from the
motor and set
aside. The
receptacle for
the Electric
Motor cord
connector is
located on
the bottom of
the Air/Electric Module Assembly (Fig. 16). Pull the
connector straight out of its receptacle only by the locking
collar. Set Motor/Cord aside. When reconnecting the motor
connector, ensure that the round dimple on the cord
connector aligns with the grooved mark on the receptacle.
IMPORTANT: The Electric Motor & Cord Assembly is not a
customer-serviceable item and should not be disassembled
in the field. Return the Motor Assembly to Aseptico if repairs
are necessary. Refer to the Sterilization Section in this
manual for more information on motor maintenance and
care. Refer to the handpiece manufacturers’ instructions for
information on handpiece maintenance and repair.
AIR/ELECTRIC MODULE ASSEMBLY
The Air/Electric Module Assembly (PN 330597) is the main
control module for the Transport III. It provides the operator
controls for the electric motor, scaler, air/water syringe, and
two suction valves.
Detach the Air/Electric Module from the Transport III unit as
outlined below: (Refer to the Operator’s Instruction Manual
for complete detailed instructions on detaching this Module.)
1. Loosen the hold-down thumbscrew that attaches the
rear housing of the Module to the connector block on the
case.
2. Pull the locking tab on the unit’s adjustable handle out
of its slot and raise the Air/Electric Module until it reaches
its highest positon (the locking tab will snap into the next
slot). The Module’s rear housing will become detached
from the connector block on the unit.
3. Locate the knob that locks the Air/Electric Module to
the adjustable handle and rotate the knob 90° so that it
aligns with the vertical slot in the handle.
4. Carefully rotate the bottom of the Air/Electric Module
away from the handle so that the knob backs out of the
slot.
5. Lift the Air/Electric Module assembly up and outward,
until its mounting bracket is free of the large opening at
the top of the handle.
6. Move the Module assembly to a work bench for
component disassembly.
HANDPIECE TUBING GUARD
The Handpiece Tubing Guard (PN 462121) protects the
tubing going to the instrument holders. It is mounted under
the instrument holder bar (Fig. 17). Use a 5/64" Allen wrench
Figure 15
Figure 17
TEE
FITTING (X3)
TUBING
GUARD
HOLDER (X4)
w/ON-OFF
TOGGLE
O-RINGS
HIGH VOLUME
EVACUATOR
(HVE)
SALIVA
EJECTOR
ELECTRIC MOTOR
& CORD ASSY
Figure 16
RECEPTACLE
ALIGNMENT
MARKS
Figure 14
RECEPTACLE
AE-7PM
FOOT CONTROL
SET
SCREW(S)
SLEEVE
CLAMP
(X17)
HOLDER
w/o ON-OFF
TOGGLE
HOLDER
BAR
HOLDER
BAR
SUPPORT
(X2)

6
to remove the two mounting screws (PN 510037).
Reassemble the Guard in the reverse order.
INSTRUMENT HOLDERS
Two Instrument Holders (PN AA-59G) with on/off toggle
controls are located at each end of the Holder Bar (Fig. 17).
A fifth toggle-less instrument Holder (PN AA-68G) is located
at the center of the bar, between the other four Holders.
Remove the Sleeve Clamps (PN 730015) from the tubing
going to each of the Holders. Remove the colored tubing
and Tee Fittings (PN 730152) going to the Holders (take note
of the tubing configurations and colors to each Holder, for
reassembly later). Back out the setscrews on the bottom of
the Holder(s) with a 3/32" Allen wrench. Remove the Holders
from the Holder Bar. Use a 5/64” Allen wrench to remove the
two mounting screws (PN 510160) that attach the Holding
Bar (PN 462095) to the Holding Bar Supports.
Reassemble the Instrument Holders in the reverse order.
Refer to plumbing schematic for proper installation.
WATER FILTER & LUER FITTING
The Water Filter (PN 730326) and Luer Fitting (PN 730073)
are located in the blue tube (PN AA-95B) that protrudes into
the water bottle (Fig. 18).
Depressurize the water bottle
and remove it from its water cap.
Remove the Luer Fitting from the
bottom section of the tube.
Loosen the sleeve clamps (PN
730095) located at the top of the
blue tube and at both ends of the
Filter. Unscrew and remove the
Filter. Remove the three fittings
(PN 730073) and gaskets (PN
730074) from the tube sections.
To clean the Filter, inject
compressed air from the top end
to unplug its screen, or replace
the filter with a new one.
Reassemble in the reverse
order, with new gaskets if
necessary.
WATER CAP GASKET
The water cap gasket (PN
730473) is located on the
underside of the white water
bottle cap (PN 462039) (Fig. 19).
Depressurize the water bottle
and remove it from its water cap.
Reach up into the white cap and
pull the black gasket from the
cap.
Reassemble in the reverse order
with a new gasket.
WATER CAP
The water cap (PN 462039) is attached under the right side
of the Air/Electric Module Top Panel (Fig. 19). Remove the
water bottle as previously described. Remove the two sleeve
clamps (PN 730015) from the two tubes, then detach the
blue tube (PN AA-94B) and clear tube (PN AA-94C) from the
fittings on the cap. Remove the three mounting screws (PN
510404) from the top of the panel (Fig. 18) with a 3/32" Allen
wrench and remove cap. Remove the two fittings (PN
730062) and gaskets (PN 730074) from the cap, using a 1/4"
open-ended wrench. Inspect and replace fittings or gaskets
if necessary.
Reassemble the cap in the reverse order. Refer to the
plumbing schematic for the proper installation of tubing.
ELECTRIC MOTOR CONTROL PANEL HOUSING
Locate the
four mounting
screws (PN
510650) on
the bottom of
the Air/Electric
Module Top
Panel (Fig.
20), and
remove with a
#2 Phillips
screwdriver.
Disconnect the
Wire Harness
(PN 875113)
from the 4-pin
'JCOMM'
connector
located on the
Motor Control
Panel Display
Board (PN
330600-C)
(see Fig. 21).
Move Motor
Control Panel
to the work-
bench.
Disconnect the Control Panel Membrane flex cable from the
6-pin 'JKEYPAD' connector on the Display Board (Fig. 22). If
removal of the Display Board is required, use needlenose
pliers to
remove hot
melt glue and
pinch together
the four
mounting
studs on the
Control Panel
Housing and
lift off the
Board. NOTE:
The Display
Board is not a
user-
serviceable
subassembly
and
Figure 20
TOP PANEL
MOUNTING SCREWS
(X4)
Figure 18
WATER
FILTER
MOUNTING
BAR
Figure 19
GASKET
CAP
DISASSEMBLY - Cont'd
LUER FITTING
SLEEVE
CLAMP
(X3)
SLEEVE
CLAMP
(X2)
WATER
CAP
MOUNTING
SCREWS
(X3)
FITTINGS
Figure 22
DISPLAY BOARD
FLEX CABLE
CONTROL PANEL MEMBRANE
MOUNTING STUD (X4)
Figure 21
TOP PANEL
ELECTRIC MOTOR
CONTROL PANEL
4-PIN
'JCOMM'
CONNECTOR

7
should be returned to Aseptico if repairs are required.
The Control Panel Membrane (PN 420918) is attached to
the front of the Panel Housing with an adhesive backing (see
Fig. 22). Removal of the Membrane is not recommended
unless absolutely necessary. If removal is required, carefully
peel the Membrane out of the recess in the Housing and
permanently discard the entire Membrane. (IMPORTANT:
Do not reuse an old Membrane - once detached, it should
always be replaced with a brand new Membrane.) To
reinstall a new Membrane: 1) Insert flex cable pigtail through
the slotted hole in the Top Cover; 2) Remove liner from
adhesive backing on new Membrane; 3) Carefully center
new Membrane in recess in Top Cover; and, 4) Press down
evenly on Membrane until firmly adhered to Cover; and 5)
Add 4-inches of 1-inch diameter heat Shrink around Flex
Cable (Do Not Shrink).
Use a 5/64" Allen wrench to remove the four screws (PN
510037) that attach the two Holder Bar Supports (PN
462096) to the Top Panel (see Fig. 21). Place Supports
aside for reassembly later.
The Rubber Seal strip (PN 520104) is adhered to the Top
Panel, along the Panel's back edge (top of Fig. 24). Peel off
the Seal if necessary. Remove backing and stick new seal
into place.
REAR WALL
Use a 5/64" Allen wrench to remove the 10 screws (PN
510037) that
attach the Rear
Wall to the
Air/Electric
Module (Fig. 24).
Note that one
mounting screw
is located on the
Manifold
Assembly control
panel and two
more are on the
top panel.
Carefully
disconnect the
Rear Wall from
the Module and
swing it to the
right, noting that
the tubing to the
Pressure Toggle
Valve (PN
730014) is still
attached.
Remove sleeve
Clamp (PN
730015) and
detach the clear
tubing (PN AA-
94C) from the
Toggle Valve.
Disconnect Rear
Wall and move to work bench. Remove the two Fittings (PN
730062) and gaskets (PN 730074) with a 1/4" open-ended
wrench. Use a 9/16" wrench to remove the Toggle Valve
mounting nut located on the outside of the Wall, then remove
the Valve.
RIGHT SIDE WALL
Locate the four mounting screws (PN 510037) that attach
the Right Wall
(PN 462036)
to the Module
(see Fig. 26).
Use a 5/64"
Allen wrench
to remove all
four screws
and set the
Wall aside for re-assembly later.
POWER BOARD AND INSULATORS
Use a 1/16" Allen wrench to remove the four screws (PN
510016) that attach the plastic Power Board Insulator (PN
462117) to the Module (Fig. 27). Remove Insulator to
expose the Power Board (PN 330601), then place Insulator
aside for reassembly later.
Carefully pull
Power Board
away from the
Module until
the wiring
assemblies
can be
accessed (Fig.
28). Note the
alignment of
the Board's
mounting
holes with the
nylon stand-
offs. Unclamp
the brass Sleeve (PN 461607) from the Pressure Sensor
Tube (PN 730227). Detach Tube from 'PSENS1' connector
on Power Board. Disconnect the Motor Connector Wiring
Assembly (PN 330598) from the 'J_MOTOR' connector on
the Board. Note the orientation of the Wiring Assembly's
connector and wires with the locking tab and position '1' on
the Board's connector. Disconnect the 3-pin, 2-pin, and 5-pin
(PN's 860118, 860076, and 860019 respectively) connectors
from the 'JPWR1', 'J_SLND', and 'J_FOOTPEDAL'
connectors on the Board.
MOUNTING
SCREWS
(X10)
Figure 24
REAR WALL
Figure 26
RIGHT WALL
MOUNTING
SCREWS (X4)
Figure 27
MOUNTING
SCREW
(X4)
POWER
BOARD
INSULATOR
TOGGLE
VALVE
FITTING
(X2)
REAR
WALL
TUBE
Figure 25 PRESSURE
RELEASE
TOGGLE
VALVE

8
Note the orientation of the connectors' wiring with the
Board's connectors. Remove Power Board from Module and
set aside for reassembly later. IMPORTANT: The Power
Board Assembly is not a customer-serviceable item. Return
the Board Assembly to Aseptico if repairs are necessary.
Pull the inboard Insulator (PN 462113) off the four nylon
mounting Standoffs (PN 462112) (Fig. 28) and place aside
for reassembly later. Unscrew, by hand, the nylon Standoffs
from the threaded studs on the Module's Front Wall and set
Standoffs aside for re-assembly later.
MANIFOLD ASSEMBLY
Locate the five mounting screws (PN 510037) for the
Manifold Assembly (PN 330591) and Manifold Wall (PN
462029) (Fig. 30), two on the top and two on the bottom of
the Module and
one on the face
of the Manifold
Control Panel.
Use a 5/64"
Allen wrench to
remove all four
screws.
Carefully pull the Manifold Assembly away from the Module
until the plumbing connections on the inboard side are
readily accessible.
SCALER-ADJUSTMENT POTENTIOMETER
The scaler
potentiometer
(part of PN
730691) is
located on the
Manifold
Assembly (Fig.
31). Loosen the
small setscrew
on the side of
the potentio-
meter knob with
a 1/32" Allen wrench and remove knob. Remove the
mounting nut on the outboard side of the Manifold Wall with
a ½" socket or open-ended wrench. From the inboard side of
the Manifold, remove potentiometer through the hole in the
Wall (see Fig. 33).
Reassemble the scaler potentiometer in the reverse order
with the lock washer positioned against the inboard side of
the Maniflold wall and the alignment pin on the potentiometer
keyed into the hole in the Wall.
MANIFOLD BLOCK
The On/Off and Air & Water Control Valves for the Scaler,
Motor/Handpiece, and Syringe are located on the Manifold
Block Assembly (Fig. 32). Cut the two wires to the Scaler
Disable Switch, PN 830144, located at the right top corner of
the back side of the Manifold (Fig. 32) and then unscrew
Switch by hand. When reassembling, note the lockwasher
(part of Switch) is positioned against the Block.
DISASSEMBLY - Cont'd
Figure 28
POWER
BOARD
INBOARD
INSULATOR
STANDOFFS (X4)
PRESSURE
SENSOR TUBE
AND CLAMP
DISPLAY BOARD
WIRE HARNESS
CABLE
CONNECTORS
Figure 30
MOUNTING
SCREWS (X5)
Figure 31
SETSCREW
SCALER
ADJUSTMENT
KNOB
MOUNTING
NUT
Figure 32
SCALER
ACTIVATION
SWITCH
SCALER
DISABLE
SWITCH
WATER
CHECK
VALVE
1/8" TUBE
SLEEVE
CLAMP
(TYP.)
35 PSI
REGULATOR

9
Use diagonal cutters or needle-nose pliers to pry off all
sleeve clamps from the tubing and hoses that connect to the
Manifold Block (Fig. 32). The 1/8" tubing is clamped with PN
730015 Clamps or PN 730096 Uni-Clamps; and, the 1/4"
tubing is attached with either large white nylon Clamps PN
730095; large brass Clamps PN 461607, or the large
aluminum Clamps PN 462230.
Detach the connecting tubes and hoses from Manifold
Block. NOTE: To simplify disassembly, at this time, only
detach the tubes and hoses that are still interconnected to
the Module Assembly -- leave the other tubes and hoses
with loose ends attached to the Block (Fig. 33). Take note
how all tubes and hoses connect to the Block. Inspect the
ends of all tubes and hoses for fraying or cracks and trim off
damaged ends before re-attaching to Block. Refer to
Plumbing Schematic Drawings for proper reassembly of
tubes and hoses.
Move Block to work bench for further disassembly. Detach
remaining sleeve clamps and tubes as necessary.
IMPORTANT: The Manifold Block (Fig. 33) is not a customer-
serviceable item. Return the Block to Aseptico if repairs are
required.
JUNCTION BLOCK
The Junction Block provides an interconnecting air, water,
and electrical terminal between the 525CF Control Module
and the Compressor Module. The Block is located in the
pivotal housing attached to the back side of the Air & Water
Manifold Module (Fig. 34a).
Use a 5/64" Allen wrench to remove the four mounting
Screws (PN 510037) that attach the Front Housing (PN
462042) to the Rear Housing (PN 462043) (Fig. 34b).
Use diagonal cutters or needle-nose pliers to pry off the
sleeve clamps from the two tubes and hose that connect to
the Junction Block (Fig. 34a). The 1/8" tubing is clamped
with Clamps PN 730015 and the 1/4" hose is attached with
a large white nylon Clamp (PN 730095).
Figure 33
Use a small flat-head screwdriver to disconnect just the
Junction Block wiring from the 7-position Terminal Block (PN
860283) located inside the Rear
Housing (Fig. 34a). Take note of
the color wiring-to-terminal
connections, for reassembly
later. Note the wiring
configuration of the Resistor (PN
810438). Refer to the electrical
schematic for proper installation.
Locate the Locking Thumbscrew
and Bracket (PN 462052) on the
side of the Rear Housing (Fig.
44a). Depress and hold the
Thumbscrew against the bracket while using a #2 Phillips
screwdriver to remove the Junction Block mounting screw
(PN 510790). Remove the other mounting screws (PN
510790) located on the opposite side of the Rear Housing
(Fig. 44b) and on the back side of the Housing. Remove the
Junction Block to the workbench for further disassembly.
MOUNTING SCREWS
FRONT
HOUSING
JUNCTION BLOCK
Figure 34a
REAR
HOUSING
1/8" TUBE
SLEEVE
CLAMP (X2)
1/4" HOSE
SLEEVE
CLAMP
FUSE
HOLDER
7-POSITION
TERMINAL
BLOCK
CAPACITORS
(X2)
RESISTOR
(PN 810438)
Figure 34b

SCALER CONTROL MODULE
The Scaler
Control Module
(PN 840140) is
located on the
upper left side
of the Manifold
Module Front
Wall. Slide the
cover of the
Scaler Module
to the left, to
expose the
wiring terminal
blocks
underneath
(Fig. 49).
Disconnect the
wiring
connector from
the Module's 12-pin receptacle. When reattaching this
connector, refer to the wiring guide imprinted on the Module
cover, or refer to the System schematic. Unless damaged,
there is no need to disconnect or remove any remaining
Scaler Module wiring - leave it in place for reassembly later.
Locate the three mounting screws (PN 510530) on the
outboard side of the Front Wall that attach the Scaler Module
to the Wall. Using a #1 Phillips screwdriver, remove the
Screws and then remove the Scaler Module. Set the Module
aside for reassembly later. Reassemble the Module in the
reverse order.
THREE-WAY VALVE
The Three-Way Valve (PN 730748) and its mounting
hardware is located
on the Front Wall
(Fig. 51).
Use diagonal cutters
or needle-nose pliers
to pry off the large
white nylon Sleeve
Clamp (PN 730095)
from the 1/4" Hose
(PN AA-95G) that
protrudes through
the large black
silicone tubing from the Rear Housing. Use a 5/64" Allen
wrench to remove the two Mounting Screws (PN 510037)
that attach the Valve to the Mounting Bracket. Leave the
Bracket (PN 462114) and Insulator (PN 462116) attached to
the Front Housing. Move the Valve and its hardware to the
workbench if further disassembly is required.
At the workbench, use a flat-head screwdriver to remove the
two Screws (PN 510688) that mount the Floating Block (PN
462052) to the Junction Block (Fig. 45). Move the Floating
Block aside and only disassemble if necessary: Use a 5/16"
open-ended wrench to remove its three large Air Junction
Fittings (PN 462051). Use a 1/4" open-ended wrench to
remove its
smaller 1/16" &
1/8" Hose
Fittings (PNs
730062 &
730073 res-
pectively) and
nylon Gaskets
(PN 730074).
Replace the
large outer O-
rings (PN
520121), or
smaller internal
O-rings (PN 520025) as necessary.
IMPORTANT: The 12-pin Connector Plug (PN 860285)
subassembly, which consists of five Wires (PN's 870304-01,
-02, -03, -04, & -06) and Contact Terminals (PN 860290),
Resistor (PN 810438), and two mounting Screws (PN
510766) are permanently epoxied to the Junction Block and
cannot be serviced. Replace the entire epoxied Connector
Plug/Junction Block subassembly if repairs are required.
NOTE: It is not necessary to disconnect any remaining
wiring from the 7-Position Terminal Block (PN 860283) (Fig.
34a) or the 4-Positon Block (PN 860250) (Fig 49), nor
remove the Blocks from the unit, unless they are faulty or
damaged.
10
DISASSEMBLY - Cont'd
Figure 44a
JUNCTION
BLOCK
MOUNTING
SCREW
Figure 44b
MOUNTING
SCREWS (X3)
NON-
SERVICEABLE
CONNECTOR
PLUG ASSY
Figure 45 MOUNTING
SCREWS (X2)
AIR JUNCTION
FITTINGS (X3)
1/8" FITTING
1/16"
FITTINGS
(X2)
LARGE
O-RINGS (X3)
FLOATING
BLOCK
RESISTOR
Figure 49
12-PIN
CONNECTOR
BLOCK
4-PIN
TERMINAL
BLOCK
Figure 51
DETACH ONLY
THIS 1/4"
CLAMP &
HOSE
3-WAY
VALVE
MOUNTING
BRACKET
MOUNTING SCREWS (X2)

SYRINGE AND SYRINGE TUBING
To replace the Syringe (PN TA-90D), remove the two sleeve
clamps (PN 730015) from the Syringe tube splices located
inside the bottom panel of the Air & Electric Module (Fig. 58).
Pull the tubing down through the grommet and move
Syringe and Tubing
Assembly to work
bench. At bench,
unscrew the bottom
handle from the
Syringe head to
access the tubing
connections (Fig.
59). Remove the
two sleeve clamps
(PN 730015) and
disconnect the tube
(PN AA-85G) from
the head.
To reassemble the
Syringe, cut
approximately 67"
of the syringe
tubing and attach to
the Syringe head with two sleeve
clamps. Place the syringe in its holder on the Air & Electric
Module and adjust the length of the tubing so that it
suspends off the floor. Splice the end of the tube as before
and attach to the two fittings on the Manifold Block with two
sleeve clamps. Verify that air comes out the syringe when
the air button is depressed and that water sprays out when
the water button is depressed.
SCALER WAND
The Scaler Wand (part of PN 730658 + 730659 + 730660) is
attached inside the Air & Electric Module (Fig. 60). Unplug
the Scaler Connector from the scaler module. Cut the Cable
Tie around the Scaler cord. Remove the Scaler Tube from
the manifold. Cut the Anchor Line wrapped around the
standoff.
At the workbench, disconnect the remaining two sleeve
clamps and
hoses from
the two
Fittings (PN
730139) (Fig.
52). Use a
1/4" thin
open-ended
wrench to
remove the 2
barbed
Fittings (PN
730073),
three Plugs
(PN 730072),
and eight
nylon
Gaskets (PN
730074). Use
a 3/8" open-ended wrench to remove the two cross Fittings
(PN 730139) and 90 degree angle fitting (PN 750537).
ELECTRIC MOTOR RECEPTACLE
The Electric Motor Receptacle Assembly (PN 330598) is
mounted onto the bottom panel of the Air & Electric Module
(Fig. 53a). Locate the 4 Mounting Screws (PN 510160) on
the bottom of the Module and remove them using a 5/64"
Allen Wrench (Fig. 53b). Move the entire Receptacle
Assembly to the workbench for further disassembly, if
necessary.
NOTE: At the
workbench, take
note how the
Adapter Plate (PN
462069) slides into
the slot on the
Receptacle. Also
note the hole-
orientation of the
Spacer (PN
462135), with the Adapter Plate and Receptacle (Fig. 57).
11
Figure 57
Figure 58
SPACER
MTG.
SLOT IN
RECEPTACLE
GROMMET
ADAPTER
Figure 59
TUBING
SLEEVE CLAMPS
(X2)
HANDLE
SYRINGE TUBING &
SLEEVE CLAMPS
HEAD
Figure 52
BARBED
FITTINGS
PN 730073
3-WAY
VALVE
CROSS
FITTINGS
PN 730139 PLUGS
PN 730072
PN 730537
Figure 53b
MOUNTING SCREWS
(X4)
MOTOR
RECEPTACLE
ASSEMBLY
Figure 53a
Figure 60
ANCHOR
LINE
CABLE TIE
SCALER
TUBE
SCALER
CONNECTOR

(PN 510765) that attach the Lock Knob (PN 462033). Then,
use a 5/64" Allen wrench to remove the two Screws (PN
510720) that mount the Spacer (PN 462034) to the Wall.
AIR BOTTLE ASSEMBLY
The Air Bottle Assembly is located inside the Transport III
Case, in the upper right-hand corner of the top compartment
(Fig. 64a). Turn the unit off and purge any residual pressure
left in the System (depress the Syringe air button to release
all air pressure). Unscrew the Air Bottle (PN 730657) from its
Lid (PN 462007) and set Bottle aside for reassembly later.
Cut the cable tie around the two gray tubes (PN AA-95G)
running to the Air Bottle Assembly (see Fig. 64b). Use a
Phillips screwdriver to remove the top mounting Screw (PN
510545) which threads into the Assembly Bracket (PN
462006), through the top of the Case. Then, use a 3/32"
Allen wrench to remove the other mounting Screw (PN
510309), which is
accessed from the
inside of the case.
Carefully pull the
Assembly out of the
Case to access its
tubing (Fig. 65). At the
Bottle Lid, remove the
Sleeve Clamp (PN
730095) and Tube (PN
AA-95G) that runs from
the Compressor
Assembly (see Fig. 65).
At the Filter (PN
730495), locate the Tube going to the Bulkhead Manifold
and use a 7/16" open-end wrench to remove it from the
straight Fitting on the
Filter. When present,
remove sleeve clamp
and clear tube from
tee.
Move the Bracket
subassembly to the
workbench. Use a
3/32" Allen wrench to
remove the two
mounting Screws (PN
510404) for the Lid
and the two Screws (PN 510309) for the Filter (see Fig. 66).
Pull the Scaler Wand cord down through the grommet in the
bottom panel of the Air & Electric Module. Remove Scaler
Wand. IMPORTANT: The Scaler Wand is not a customer-
serviceable item. Return the Wand to Aseptico if repairs are
required.
Reassemble the Scaler Wand in the reverse order, adjusting
the length of the Wand cord to hang suspended off the floor
and then trimming the excess cord and/or water line. Wrap
the cable tie around the scaler cord and through the tie wrap
mount. Ensure that the tie is not over-tightened and does not
restrict the flow of water. Attach the anchor line around the
nearby standoff and then tie it to the tie wrap mount. Attach
the green, white, and black wires from the Wand to
connector on the scaler module using 860020 connector
housing and (5) 860023 connector crimp pins according to
the sheet 4 diagram of the schematic drawing set (330597).
Check to ensure that scaler water flow is appropriate.
FOOTSWITCH CONNECTOR
The Footswitch Connector (PN 860212) is located on the
bottom panel of the
Air & Electric
Module. Use a
13/16" open-ended
wrench to remove
mounting nut on
outboard side of
bottom panel (Fig.
61). (NOTE: Take
care to protect the
panel against
scratches when
removing nut.) Push
Connector inward
through 'D' shaped
cutout in bottom
panel of the Air &
Electric Module.
Note that the
keyway on the
threaded Connector
is pointing toward
the right-hand side. Remove entire Connector and wire
harness assembly and set aside for reassembly later.
(NOTE: During reassembly, ensure that the rubber gasket
that is supplied with the Connector (see Fig. 62) is
positioned on the inboard side of bottom panel.
AIR/ELECTRIC MODULE LOCK-
KNOB & HANDLE
The Air/Electric Module Locking
Knob and Handle are located on the
Front Wall (Fig. 63). If the Handle
(PN 462031) needs to be removed,
use a 5/64" Allen wrench to remove
its two mounting Screws (PN
510037). The Locking Knob
consists of six different parts:
Use a 1/8" Allen wrench to
remove the large shoulder
Screw (PN 510767) and Spring
12
HANDLE
Figure 63
Figure 61
MOUNTING
NUT
FOOTSWITCH
CONNECTOR
KEYWAY
Figure 62
'D' SHAPED
CUTOUT
FOOTSWITCH
CONNECTOR
W/WIRE
HARNESS
RUBBER
GASKET
LOCK
KNOB
SHOULDER
SCREW
SPRING
KNOB
SPACER
Figure 65
1/4" SLEEVE
CLAMPS
(X2)
BOTTLE CAP
MOUNTING SCREWS
BUMPER
PAD (X2)
Figure 66
FILTER
MOUNTING SCREWS
LID GASKET
Figure 64b
Figure 64a
AIR
BOTTLE
ASSEMBLY
CABLE
TIE
FILTER
ASSY
MOUNTING
SCREW
MOUNTING
SCREW
DISASSEMBLY - Cont'd
TUBE
FROM
COMPRESSOR
ASSEMBLY
TUBE TO
BULKHEAD
MANIFOLD

Assembly out of the Case
and place in front of Case
temporarily. Leave all tubing
attached.
A Top Panel (PN 462063)
covers the Compressor
Assembly (Fig. 72). Use a
5/64" Allen wrench to
remove the six Screws (PN
510037) that mount the
Panel to the Compressor.
Remove Panel (see Fig. 73) and place aside for reassembly
later. If the Handle (PN 850075) on the Panel needs
replacment, use a 4mm Allen wrench to remove the two
mounting Screws (PN 510717) and Lockwashers (PN
510420).
VACUUM HOSE
FITTINGS
Locate the Air/
Electric Manifold
Door on top of the
Case. Open Door
to access the High
and Low Vacuum
Hose end Fittings
inside the Bulkhead
Insert (Fig. 74a).
Use adjustable
channel lock pliers
to pry off the
Ferrule (PN
462138) and then the Fitting (PN 462021) on the larger High
Vacuum Hose (PN AA-259) (see Fig. 73b). Inspect O-Ring
(PN 520101) for
wear and replace if
necessary. Next,
remove Ferrule (PN
462139) and Fitting
(PN 462022) on the
Low Vacuum Hose
(PN 730794) (Fig.
74b). Inspect O-
Ring (PN 520100)
for wear and replace if necessary. Pull both Vacuum Hoses
ends down through the Bulkhead Insert. Leave opposite
ends attached to the Compressor Assembly (Fig. 75).
BULKHEAD
TUBES
Use diagonal cutters
to pry off the 1/8" &
1/4" Tube Sleeve
Clamps (PNs
730015 & 730095)
(Fig. 76). Then,
remove the Red
Tube (PN AA-94R),
Green Tube (PN AA-
94G), and Gray Tube (PN AA-95G) from their fittings. Leave
the opposite ends of the Tubes attached to the Compressor
Assembly.
Inspect and replace the two Bumper Pads (PN 850067) if
necessary. Clean or replace Filter (PN 730495) as
necessary. Check Bottle Gasket (PN 730473) located inside
the Lid (Fig. 65) for wear/leakage and replace as necessary.
DIVIDER WALL
The Divider Wall
(PN 462000) is
located in the top
compartment of the
Transport III Case
(Fig. 67). Use a
5/64" Allen wrench
to remove the five
lower mounting
Screws (PN
510037). Cut tie
wrap holding LVE
hose (AA-86G) to barb feedthrough (PN 730558) and
remove. Squeeze HVE hose slightly, remove Divider Wall
and set aside for reassembly later. To remove the Bungee
Cord (PN 730370), untie the knot in the Cord and pull the
Cord up through the rubber Grommet (PN 870326). Place
Cord aside for reassembly later. Inspect and replace plastic
Hook (PN 730371) if damaged. The storage strap (PN
462145) can be removed from the Divider Wall by pulling
apart the hook-and-loop connector and replaced if needed.
COMPRESSOR ASSEMBLY TOP PANEL
The entire
Compressor
Assembly can be
detached and pulled
out of the Transport
III Case for
component
disassembly.
Use a 3/32" Allen
wrench to remove
the two mounting
Screws (PN
510404) located on the
Compressor Top Panel (see
Fig. 71a). Use a 5/32" Allen
wrench to remove all the
Compressor Assembly
mounting hardware located
on the bottom of the Case
(see Fig. 71b).
Pull the High Vacuum and
Low Vacuum Hoses down
inside the Case top
compartment, to provide
slack when removing the
Compressor Assembly (see
Fig. 72). Carefully pull the
entire Compressor
13
HIGH VAC HOSE
Figure 72
COMPRESSOR ASSY
Figure 67
DIVIDER
WALL
LOWER
MTG.
SCREWS
(X5)
Figure 71a
COMPRESSOR
TOP PANEL
Figure 71b
MOUNTING
HARDWARE
MOUNTING
SCREWS
BUSHING
(PN 520118)
WASHER
(PN 510837)
SCREW
(PN 510294)
SCREW
(PN 510295)
BUMPER
(PN 850082)
WASHER
(PN 510837)
BUSHING
(PN 520118)
LOW VAC
HOSE
TOP
PANEL
Figure 73
(TOP PANEL REMOVED)
Figure 74a LOW VAC
HOSE
HIGH VAC HOSE
Figure 74b LOW VACUUM
HOSE FITTING
HIGH VACUUM
HOSE FITTING
(FERRULES)
(O-RINGS)
BULKHEAD
INSERT
Figure 75
VACUUM
HOSES COMPRESSOR ASSY
1/8" TUBES 1/4" TUBE
SLEEVE CLAMPS
Figure 76

and follow it's leads to the two power supplies on the
Electrical Panel (Fig. 80).
Cut the three Cable Ties (PN 510137) that secure the
Display Module Power Cable to the Electrical Panel (Fig.
80). Leave the three Tie Mounts (PN 510179) in place, for
reassembly later. Use a 5/16" open-ended wrench to
remove the Power Cable Grounding Nut (PN 510293) and
Lockwasher (PN 510419) from the stud on the Electrical
Panel (see Fig. 80).
48V POWER SUPPLY
The 48V Power Supply (PN 840087-01) provides power to
the Electric Motor Assembly. Detach the Power Cable 2-wire
connector from the 'CN2" 4-pin receptacle on the Supply's
PCB (Fig. 81a). Note the orientation of the connector to the
PCB receptacle latch and pin-position of red wire.
24V POWER SUPPLY
The 24V Power Supply (PN 840120) provides power to the
Scaler Assembly. To access the Supply's power connector,
which is situated on the Supply's underside, the Supply must
first be removed from its mounting Standoffs and turned
over. Use a 1/16" Allen wrench to remove the four Screws
(PN 510016) and Washers (PN 510573) that secure the
Supply to the four Standoffs (PN 462244). Carefully lift the
Power Supply off the Standoffs, then detach the Power
Cable's 2-wire connector from the 'CN2' 4-pin receptacle on
the Supply's PCB (Fig. 81b). Note the orientation of the
connector to the receptacle latch and the pin-position of the
blue wire. Detach the other 2-wire connector from the 'CN1'
receptacle on the Supply's PCB, then set the 24V Power
Supply aside for reassembly later. Also note the orientation
of this connector to its receptacle latch. Unscrew the four
Standoffs (PN
462244) from their
studs on the
Electrical Panel and
place aside for
reassembly later.
Note position of one
(1) 462244-01
standoff which is
modified from the
other standoffs.
IMPORTANT: The
24V Power Supply is
not a customer-serviceable item. Replace the entire Supply
or return it to Aseptico if repairs are required. Locate the
Cable Clamp (PN 510410) for the Display Module Power
Locate the Cable Tie (PN 510137) that straps the Display
Module Power
Cable (PN 875118)
to the Compressor
Assembly (see Fig.
77). Cut the Tie to
provide additional
slack for the Power
Cable.
Carefully rotate the
Compressor
Assembly onto its
back side (see Fig. 78) (Place a protective pad under the
Assembly to prevent scratching.)
MOTOR HOUSING COVER
Locate the four mounting Screws
that attach the Motor Housing
Cover to the Compressor
Assembly (see Fig. 78). Use a
5/64" Allen wrench to remove the
Screws (PN 510036), Metal
Washers (PN 510431), Rubber
Washers (PN 510827) and Blue
Washers (PN 510936). Carefully
lift the Cover off the Compressor
Assembly and set aside until
reassembly later (see Fig. 79)
ELECTRICAL PANEL
The Electrical Panel is located beneath the Motor Housing
Cover (Fig. 79). Locate the Display Module Power Cable
14
DISASSEMBLY - Cont’d
Figure 77
CABLE
TIE
DISPLAY MODULE
POWER CABLE
Figure 78
DISPLAY
MODULE
PWR CABLE MTG. HARDWARE
(X4)
(MOTOR HOUSING COVER)
ROTATE
COMPRESSOR
ASSEMBLY
Figure 79
ELECTRICAL PANEL
MOTOR HOUSING COVER
DISPLAY MODULE
POWER CABLE
24V PWR SUPPLY
CONNECTOR
48V PWR SUPPLY
CONNECTOR
CABLE TIE (X3)
GROUND WIRE
MTG NUT
Figure 80
Figure 82 MANIFOLD INSERT
CABLE CLAMP
DISPLAY MODULE POWER CABLE
Figure 81b
Figure 81a
48V POWER SUPPLY
4-PIN RECEPTACLE
2-WIRE
CONNECTOR
GROUND
WIRE RECEPTACLE
2-WIRE
CONNECTOR
24V POWER SUPPLY
(Underside)

CONTROL BOARD PCB
A smaller 24V Power Supply (PN 840093) provides power to
the Electronic Control Board (PN 330604) (Fig. 85). This
Power Supply is mounted to the top of the Control Board
PCB with a tie wrap and can be detached if necessary.
Detach the three flag-type wire terminals from connectors
'T1', 'T2', and 'T3' on the Control Board PCB (see Fig. 86).
Note the color-arrangement of the wires and the connectors.
Next, detach the three wire connectors at the PCB sockets
marked 'J_WASTE', 'J_SOL', and 'J_LEDS'. Note the
alignment of the
connectors to the
socket latches, and
the wire color
positions. Use a
1/16" Allen wrench
to remove the four
mounting Screws
(PN 510016), split
lockwashers (PN 510433), and flat nylon washers (PN
510657) that mount the Control Board PCB to the four
Standoffs (PN 510760). Next, use a 5/64" Allen wrench to
remove the mounting Screw (PN 510160) that attaches the
Heatsink (PN 462111) to the PCB. Carefully lift the Control
Board Assembly off the Standoffs and move to a workbench
for further disassembly. Use a 1/4" open-ended wrench to
remove the four Standoffs then remove the Insulator Pad
(PN 462080) and set aside for reuse later.
At the workbench, cut and remove the Cable Tie (PN
510628) that straps the Power Supply to the Control Board
PCB. Lift the Power Supply straight up and off the mounting
pins on the PCB . IMPORTANT: The Power Supply and
Control Board PCB assemblies are not customer
serviceable. If repairs are required to either assembly,
replace the entire item or return it to Aseptico for service.
Cable, which is
mounted inside the
Case, just below the
Manifold Insert (see
Fig. 82). Use a 3/32"
Allen wrench to
remove the Clamp
mounting Screw (PN
510404). Remove
Clamp and set aside
for reassembly later.
DISPLAY MODULE POWER CABLE
At the top of the case, open the door to the Manifold Insert
and locate the Display Module Power Cable 12-Pin Socket.
This Socket is mounted into the center of the Insert housing
with two integral screws (see Fig. 83). Use a Phillips
screwdriver to remove the two mounting screws, then feed
the entire Power
Cable up and out
through the Insert
housing. Place the
Cable Assembly
aside for reassembly
later. Inspect the
Cable for damage or
faults and replace
entire Cable if
problems are found.
Detach the remaining 2-wire connector from the 'CN1'
receptacle on the 48V Power Supply (Fig 84). Note the
orientation of the 2-wire connector to the receptacle latch.
Use a 1/16" Allen wrench to remove the four Screws (PN
510016) and Washers (PN 510573) that secure the Supply
to the four Standoffs (PN 462244). Carefully lift the Power
Supply off the Standoffs. and set aside until reassembly
later. Unscrew the four Standoffs on the Electrical Panel and
place aside for reassembly later. Remove the Insulator Pad
(PN 462081) under the Standoffs and set aside for
reassembly later. IMPORTANT: The 48V Power Supply is
not a customer-serviceable item. Replace the entire Supply
or return it to Aseptico if repairs are required.
STALL SENSING SWITCH:
Use diagonal cutters to pry off the Sleeve Clamp (PN
730015) and 1/8" clear Tube (PN AA-94C) that is attached
between the Stall Sensing Switch (PN 875120) and the
Venturi Muffler Assembly #2 (see Fig. 105b). Use a 9/16"
open-end wrench to loosen the mounting nut on the top side
of the Switch, then spin the nut and lockwasher (part of
Switch Assembly) off the threads. Pull the Switch wires down
through the mounting hole slot in the Bracket. Remove cable
tie holding down stall switch wires going to J_PRESS_SW
on the CONTROL BOARD PCB. Remove cable ties holding
the rest of the wires going to J_PRESS_SW. Disconnect
two red quick disconnects (PN 860239) which are attached
to J_PRESS_SW. Remove J_PRESS_SW from CONTROL
BOARD PCB and set aside the 875120 wire assembly for
reuse later.
15
Figure 83
MANIFOLD INSERT
(INSERT
DOOR)
DISPLAY MODULE POWER CABLE
12-PIN SOCKET
MTG.
SCREW
(X2)
48V POWER SUPPLY
Figure 84
'CN1'
RECEPTACLE
INSULATOR
PAD
Figure 86 'J_SOL'
CONNECTOR
'J_LEDS'
CONNECTOR
'T3' 'T1' 'T2'
(24V PWR
SUPPLY)
CONTROL
BOARD
PCB
CABLE
TIE
CONTROL
BOARD
PCB
MOUNTING
PINS (X4)
24V POWER SUPPLY
Figure 85
'J_PRESS_SW'
CONNECTOR
'J_WASTE'
CONNECTOR
STANDOFF
(X4) HEATSINK
INSULATOR
PAD

colors and terminal positions of the eight wires coming from
the Compressor Motor Assembly. Use a 1/8” flat blade
screwdriver to detach these eight wires from the Block.
NOTE: When
rewiring the
System, refer to
the Final
Assembly Wiring
Schematic (sheet
19, drawing
330838). Move
the Electrical
Panel to the work bench for further disassembly (Fig. 90).
COOLING FAN
The Cooling Fan (PN 540014) is located on the Electrical
Panel (Fig. 90). On the front side of the Electrical Panel,
remove the three screws (PN 510160) that mount the Fan to
the Panel with a 5/64" Allen wrench. Remove Fan.
Reassemble Fan in the reverse order with the air flow
indicator on the Fan pointing away from the front side of the
Panel. Refer to the Final Assembly Wiring Schematic for
proper installation. Be sure wires exit fan closest to the top
edge of Control Board PCB.
WASTE CONNECTOR CABLE ASSEMBLY
Locate the Waste
Connector Cable
Assembly Bracket
(Part of Cable Assy
PN 875114) (Fig.
87). Cut the two
Cable Ties (PN
510137) that
bundle the wiring to
the Control Board
Assembly (see Fig. 86 above). Use a 5/64" Allen wrench to
remove the two mounting Screws (PN 510037 and 510881
and spacer PN 510152) for the Bracket. CAREFULLY
remove Bracket and cable assembly from around PCB
assembly 330870 and set aside for reassembly later.
FAN FILTER
Carefully remove the four quick disconnect terminals from
the PN 330870 Assembly and remove screw (PN 510881)
and spacer (PN 510128) which also holds the fan (PN
540014).
ELECTRICAL PANEL 10-POS TERMINAL BLOCK
Rotate the Compressor Assembly so the Electrical Panel is
facing forward (Fig. 88). Locate the two red wire connectors
from the Unloader Solenoid
Cable Assembly (PN
875115) in the upper right-
hand corner of the Panel
(see Fig. 88 inset).
Disconnect and tag wire
connectors. Cut all cable ties
located on the front of the Electrical Panel and along the
edge of the Cooling Fan.
Locate the four mounting Screws (PN 510037) that attach
the Electrical Panel to the Compressor Assembly (see Fig.
88) and remove them using a 5/64" Allen wrench. Carefully
lower the top front edge of the Panel downward to expose
the back side of the Panel (Fig. 89).
Locate and detach the green/yellow ground wire from the
Compressor to the grounding hardware on the back side of
the Electrical Panel, using a 5/16" open ended wrench.
Locate the 10-Position Terminal Block (PN 860278) on the
back side of the Electrical Panel (Fig. 89). Note the wire
16
DISASSEMBLY - Cont’d
Figure 87
WASTE
CONNECTOR
BRACKET
Figure 88
CABLE TIE (X2)
MTG SCREW (X2)
CABLE
TIES
(X8)
MOUNTING
SCREWS (X4)
(ELECTRICAL PANEL ROTATED FORWARD)
Figure 89
(TAG WIRE
CONNECTIONS)
GROUND WIRE
MTG HARDWARE
COMPRESSOR
GROUND WIRE
COMPRESSOR
MOTOR WIRING
TERMINAL
BLOCK
Figure 90 ELECTRICAL PANEL BACK SIDE
COOLING
FAN
PANEL FRONT SIDE
MTG SCREWS
(X4)

Remove the six red flag-type wire connectors from the
terminals on the Compressor Breaker.
Cut the three cable ties (PN 510137) around the wire
bundles on the back side of the Panel (see Fig. 92). Locate
the red and orange wires from the Voltage Selector Switch
and trace them back to the 10-position terminal block (see
Fig. 92 Inset). Use a 1/8” flat blade screwdriver to detach the
two wires from positions
#1 and #2.
At the Voltage Selector
Switch carefully pull the
red and orange wires
through the terminal
block grommet and all the
way through the wire
bundle heatshrink tube (Fig. 93).
At the Voltage Selector Switch, locate the crimp that
connects the three blue wires together. At the crimp, cut the
single blue wire that leads directly to the Voltage Selector.
NOTE: During reassembly, reconnect the three blue Voltage
Selector wires shown here using a Panduit Model CT-1551
crimp tool, or equivalent tool capable of #22-10 AWG
contour crimps. When reconnecting a new flag terminal to
the black wire shown here, use a Molex Model 640014100
tool, or equivalent tool capable of crimping flag terminals.
On the front side of the Electrical Panel, use a 5/64" Allen
wrench to remove the three Screws (PN 510037) that mount
the Circuit Breaker Cover (PN 462017) to the Electrical
Panel (see Fig. 94).
Move the Cover
subassembly to a
work bench for
component
disassembly if
required (see Fig.
95).
Use a 9/16" open-
ended wrench or
pliers to loosen the
mounting nut on
the inboard side of the Voltage Selector Switch (Fig. 95).
Back the nut off the Switch by hand and then slide the nut off
the four wires. Pull the Switch and four wires through the
front side of the Cover and set aside for reassembly later.
Detach the two leads on the LED Cable
CIRCUIT BREAKERS
The Circuit Breaker Housing (PN 462017) is located on the
front of the Electrical Panel. The Housing provides an
enclosure for the Power Entry Circuit Breaker (PN 840119),
Compressor Circuit Breaker (PN 830151), and the Voltage
Selector Switch (PN 840084) (see Figs. 91 & 92).
Note the wiring configuration on the back side of the Circuit
Breaker Housing. Tag the mating female wire terminals at
each Breaker terminal to assure proper rewiring later - refer
to Electrical Schematic in Final Assembly Drawing (sheet 19,
drawing 330838) for proper wiring configuration. Locate the
green/yellow grounding wire from the power inlet socket on
the Power Entry Circuit Breaker (Fig. 92). Use a 5/16" open-
ended wrench to
remove the two
Grounding Nuts
(PN 510293) and
Lockwashers (PN
510419). Re-
move the three
blue female wire
connectors from
the three
terminals on the
power inlet socket. Set the Ground Wire aside for
reassembly later. Remove the two blue flag-type wire
connectors from the
terminals on the
Power Entry Circuit
Breaker and set the
two wires aside.
17
Figure 91 ELECTRICAL PANEL BACK SIDE
POWER
ENTRY
GROUND
WIRE
POWER
ENTRY
CIRCUIT
BREAKER
COMPRESSOR CIRCUIT BREAKER
VOLTAGE
SELECTOR
SWITCH
POWER
INLET
SOCKET
Figure 92
(ORANGE: POS 2)
CABLE TIES
(X3)
VOLT SELECTOR WIRE/TERMINAL
(RED: POS 1)
VOLTAGE
SELECTOR
SWITCH
RED &
ORANGE
WIRES
Figure 93
RED &
ORANGE
WIRES
CUT THIS
WIRE HERE REMOVE THIS FLAG TERMINAL
VOLTAGE
SELECTOR
SWITCH
Figure 94
CIRCUIT BREAKER COVER
MOUNTING SCREWS
(X3)

MOTOR HOUSING - LEFT WALL ASSEMBLY
The Left Wall (PN 462010) of the Motor/Compressor can be
detached as a subassembly and then moved to a work
bench for component disassembly.
Cut the four Cable
Ties (PN 510137)
around the Low
Vacuum Hose (PN
730794) (Fig. 97).
Use pliers to pry off
the three large
Hose Clamps (PN
510425) around the
two High Vacuum
Hose sections
(PN AA-259).
Remove the
High and Low
Vacuum Hoses
from their fit-
tings and place
aside for reas-
sembly later.
Unplug the
Motor Capacitor
and cut the
cable ties that
attach it to the
left wall.
On the inboard side of the Left Wall Assembly, in the lower
left-hand corner, locate the red 1/8" Tube (PN AA-94R),
which leads from the Switching Module Manifold Assembly
(see Fig. 97 inset). Use diagonal cutters to work the 1/8"
Sleeve Clamp (PN 730015) off the Tube, then disconnect
the Tube from the fitting on the Vacuum Valve.
Use a 5/64" Allen wrench to remove the two mounting
Screws (PN 510160) located at the base of the Left Wall
Assembly (see Fig. 97 inset).
Assembly (PN
875117) from the
two LED Diffuser
Lenses (PN
850078). Slide
Grommet (PN
870185) out of hole
in circuit breaker
cover around LED
wires. Carefully pull
the LED Cable
Assembly out of the
Housing and set
aside for reassembly later. Cut the silicone RTV locking the
circuit breakers in place. Use a small flat screwdriver to
depress the locking tabs located on the sides of the Power
Entry and Compressor Breakers and pull each Breaker out
through the front
side of the Housing.
Set the Breakers
and the Housing
aside for
reassembly later.
Replace Breakers if
necessary.
POWER INLET LINE FILTER (EMI)
The Power Inlet Line Filter (PN 840121) is mounted to the
back side of the Electrical Panel (Fig. 96). Disconnect the
four terminals/wires attached to the Filter. Use a 5/64" Allen
wrench to remove the two mounting Screws (PN 510037).
Remove Filter and set aside for reassembly later. Replace
Filter if necessary.
18
DISASSEMBLY - Cont’d
Figure 95
VOLTAGE
SWITCH
MOUNTING
NUT
LOCKING TAB (Typical)
LED
DIFFUSER
LENS (X2)
LED CABLE ASSY
COMPRESSOR
CIRCUIT
BREAKER
POWER
ENTRY
CIRCUIT
BREAKER
GROMMET
Figure 96
EMI FILTER
MOUNTING
SCREWS (X2)
Figure 97
CABLE
TIES
(X4)
MOTOR
CAPACITOR
HIGH
VACUUM
HOSE
LEFT WALL ASSEMBLY
HOSE
CLAMPS
(X3)
LOW
VACUUM
HOSE
VACUUM
SPLITTER
MTG
SCREWS
(X2)
SWITCHING
MODULE MANIFOLD TUBE
SLEEVE
CLAMP
VACUUM
VALVE
LOW
VAC
HOSE