THREE-WAY SOLENOID - Fig. 2
Remove pump cover as previously described (refer to “Power
Supply” disassembly procedure above). Disconnect tube
from pump to the valve at the valve. Remove screws from the
pump and move the pump forward. Remove tube to valve
output at the valve. Disconnect wire from the power board
and remove the two screws and washers from the valve with
a 1/16-inch Allen wrench.
Reassemble solenoid in the reverse order.
TWO-WAY SOLENOID - Fig. 2
Remove pump cover as previously described under “Power
Supply” disassembly procedure. Remove screws from the
pump and suspend the pump from the back of the chassis.
Remove the two screws and washers to the valve from the
bottom of the chassis with a 1/16-inch Allen wrench. Clip the
cable ties on the wiring harness on the chassis at the bottom
of the power board. Disconnect the connector with the two
blue wires and remove the tubes from the valve.
Reassemble solenoid in the reverse order and re-tie cables
with cable ties.
PRESSURE SWITCH - Fig. 2
Remove pump cover as previously described under “Power
Supply” disassembly procedure. Disassemble the pump as
described above under “Two-Way Solenoid”. Clip the cable ties
on the wire harness on the chassis at the bottom of the power
board. Remove the vehicle receptacle with a 1/4-inch wrench to
access the nuts and washers on the pressure sensor bracket.
Remove the nuts to the bracket with a 1/4-inch wrench.
Disconnect the tube to the pressure sensor. Remove the
pressure sensor locknut with a 7/8-inch wrench. Remove 2-pin
connector with the black and green wires from the power board.
Reassemble sensor in the reverse order.
To set pressure on the pressure sensor, remove the rear access
screw with a 1/8-inch Allen wrench to expose the adjustment
setscrew within the sensor. Adjust the sensor by turning the
setscrew with a 1/8-inch Allen wrench until the pressure reads
approximately 22 PSI on the gauge (with chassis power turned
on). Turning the setscrew clockwise increases the pressure
setting; counterclockwise decreases the pressure setting.
DISASSEMBLY
NOTE: This system consists of two main assemblies: the
chassis assembly and the battery packs. All operating
functions of the system are encased in the chassis and can be
operated outside of the unit case if proper precautions
against electrical shock are taken.
CHASSIS REMOVAL
Stand the unit upright, into its operating position. Remove
the water bottle. Go to the rear of the case and remove the
two upper screws with a #2 Phillips head screwdriver. Go to
the top of the unit and remove the two screws while
supporting the chassis with your hand. Remove the chassis
from the case.
Reassemble the chassis in the reverse order. Check the O-
rings on the screws to ensure they are not damaged. If the O-
rings are damaged, replace with new screws or RTV screws in
place.
POWER SUPPLY - Fig. 1
Remove the connectors to the power supply board on the
pump cover. Remove the three flat head screws from the
front of the chassis cover with a #2 Phillips head screwdriver.
Remove the pump cover/power supply subassembly from the
chassis. With the subassembly removed, disassemble the
power supply from the pump cover by removing the four nuts
and lockwashers from the four corners of the power supply
with a 3/16-inch wrench.
Reassemble power supply in the reverse order. When
replacing the pump cover on the chassis, take care that the
wires and tubes are not pinched by the chassis, and that the
wires from the motor and solenoid are in the appropriate slot
in the rear of the pump cover.
COMPRESSOR PUMP - Fig. 2
Remove pump cover as previously described (refer to “Power
Supply” disassembly procedure above). Remove tubes from
the air filter and three-way solenoid at the components.
Remove air supply bottle and remove the two screws to the
pump from the bottom of the chassis with a 3/32-inch Allen
wrench. Remove connector from power board.
Reassemble pump in the reverse order.
Page 5
Figure 1
Pump
Cover
Power
Supply
Figure 2
Pump
Two
Way
Solenoid
Tubes
Air Bottle
Pressure
Switch
Access
Screw
Three
Way
Solenoid
Fuse
Holders
Connectors
