TechnicalOrder_Coffee_Maker_5_20_24.pdf

TO 13B6-5-1

TECHNICAL MANUAL

OPERATION AND

MAINTENANCE INSTRUCTIONS

WITH ILLUSTRATED PARTS BREAKDOWN

ORGANIZATIONAL AND INTERMEDIATE

COFFEE MAKER

PN 50405-200

Nordskog Industries, Inc.

Manual Prepared by Serv-Air, Inc.

DAAB07-92-Z-B506

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT B - Distribution authorized to U.S. Government Agencies only (Administrative or Operational Use) (30 April 1995).

Other requests for this document shall be referred to 406 SCMS/GULAC, Robins AFB, GA 31098. Questions concerning technical content shall be referred to ES WR-ALC/GRVBAA.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

30 APRIL 1995 CHANGE 1 - 7 FEBRUARY 2012

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

*Zero in this column indicates an original page.

USAF

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Dates of issue for original and changed pages are:

Title A i - ii S1 - S2 1-1 - 1-2 2-1 2-2 Blank 3-1 3-2 Blank 4-1 - 4-3 4-4 Blank 5-1 - 5-16 6-1 - 6-2 7-1 - 7-16 7-17 Blank 7-18 7-19 - 7-21 Added 7-22 Blank

Original. . . . . . . . . .0 . . . . . . . 30 April 1995 Change . . . . . . . . . . 1 . . . . . 7 February 2012

A Change 1

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 56 , CONSISTING OF THE FOLLOWING:

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . ii

LIST OF TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii

SAFETY SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . S1

1 INTRODUCTION AND DESCRIPTION . . . . . . . . . . 1-1

1-1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-3 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-4 Capabilities and Features . . . . . . . . . . . . . . . . . . 1-1

1-5 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-6 ESDS Explanation . . . . . . . . . . . . . . . . . . . . . . .1-1

2 SPECIAL TOOLS AND TEST EQUIPMENT . . . . . . . 2-1

2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 Consumable Materials . . . . . . . . . . . . . . . . . . . .2-1

3 PREPARATION FOR USE AND

SHIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-2 Preparation for Storage or Shipment . . . . . . . . . . . . . . .3-1

4 OPERATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . 4-1

4-1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Operating Instructions. . . . . . . . . . . . . . . . . . . . . 4-1

4-3 Cold Weather Procedures . . . . . . . . . . . . . . . . . . 4-2

4-4 Controls and Indicators. . . . . . . . . . . . . . . . . . . . 4-3

5 MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . 5-1

5-1 General Requirements. . . . . . . . . . . . . . . . . . . . . 5-1

5-2 Operational Checkout . . . . . . . . . . . . . . . . . . . . . 5-1

5-3 Inspection and Preventive Maintenance . . . . . . . 5-1

5-8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

6 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

7 ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . 7-1

7-1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-3 Finding Part Numbers, Illustration, Description . . . . . . . . . . . . . . . . . . . 7-1

7-4 Similar Assemblies . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-5 Sheet Number Explanation . . . . . . . . . . . . . . . . . 7-1

7-6 Usable On Codes . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-7 Source, Maintenance, And Recoverability (SMR) Codes . . . . . . . . . . . . . . . 7-1

7-8 Parts Standardization . . . . . . . . . . . . . . . . . . . . . 7-1

7-9 Manufacturer’s List. . . . . . . . . . . . . . . . . . . . . . . 7-1

7-10 Maintenance Parts List . . . . . . . . . . . . . . . . . . . . 7-2

7-11 Numerical Index . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-12 Reference Designation . . . . . . . . . . . . . . . . . . . . 7-3

Change 1 i

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Coffee Maker and Rail Assembly . . . . . . . . . . . . . . . 1-2

4-1 Coffee Maker Operation . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Coffee Maker Draining . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-3 Coffee Maker Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

5-1 Coffee Maker Push Button Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-2 Coffee Maker PC Board Removal . . . . . . . . . . . . . . 5-5

5-3 Coffee Maker Warming Pad Removal . . . . . . . . . . . 5-6

5-4 Coffee Maker Plumbing Installation. . . . . . . . . . . . . 5-7

5-5 Flow-Control Valve Repair . . . . . . . . . . . . . . . . . . . . 5-8

5-6 Coffee Maker Repair. . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5-7 Heating Element Removal . . . . . . . . . . . . . . . . . . . 5-10

5-8 Liquid Level Probe Replacement . . . . . . . . . . . . . . 5-11

5-9 Brew Chamber Removal . . . . . . . . . . . . . . . . . . . . . 5-12

5-10 Brew Head Assembly . . . . . . . . . . . . . . . . . . . . . . . 5-13

5-11 Actuator Arm and Server Retaining Arm Replacement . . . . . . . . . . . . . . . 5-14

5-12 Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5-13 Rail Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . 5-16

6-1 Coffee Maker Electrical Schematic . . . . . . . . . . . . . 6-2

7-1 Coffee Maker and Rail Assembly. . . . . . . . . . . . . . . 7-6

7-2 Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-3 Actuator Arm Assembly and Server Retaining Arm Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-4 Brew Head Assembly and Probe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

7-5 Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . 7-14

7-6 Plumbing Installation . . . . . . . . . . . . . . . . . . . . . . . 7-18

7-7 Coffee Maker Rail Assembly . . . . . . . . . . . . . . . . . 7-20

LIST OF TABLES

Number Title Page Number Title Page

1-1 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2-1 Special Tools and Test Equipment . . . . . . . . . . . . 2-1

2-2 Consumable Materials . . . . . . . . . . . . . . . . . . . . . 2-1

5-1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 ii Change 1

----fif/’--^_ ^^B^iis^ i^h

SAFETY SUMMARY

The following are general safety precautions and instructions that personnel must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of Air Force property. Portions of this summary may be repeated elsewhere in this publication for emphasis.

OBSERVE WARNING AND CAUTION STATEMENTS

WARNING and CAUTION statements have been strategically placed throughout this manual to emphasize certain steps or procedures for the protection of personnel (WARNING) or possibility of equipment and property damage (CAUTION).

A WARNING or CAUTION, once provided, will apply each time the related task is performed, regardless of the number of times the step is repeated throughout the manual. Prior to starting any task, review and understand the WARNINGS and CAUTIONs included in this manual for that task.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must observe all safety regulations at all times. Do not replace components inside the equipment with voltage supply turned on. Under certain conditions, dangerous potentials may exist when power control is in the OFF position due to charges retained by capacitors. To avoid injuries, always remove power from discharge and ground a circuit before touching it. Adhere to all lock out/tag out requirements.

DO NOT WEAR JEWELRY

Remove rings, watches, and other metallic objects which may cause shock or bum hazards. Snagged finger rings have caused many serious injuries. Unless specifically allowed by shop safety procedures, remove finger rings during all periods of maintenance.

DO NOT SERVICE OR ADJUST ALONE

Do not attempt internal service or adjustment with power applied unless another person capable of rendering aid and resuscitation is present. Personnel working with or near dangerous voltage shall be trained in modem methods of resuscitation. Information and training sources may be obtained from the director of base medical services.

^^ USE ELECTROSTATIC DISCHARGE (ESD) PROCEDURES

Certain circuit card assemblies and their components will be damaged by seemingly undetectable electrostatic discharge.

Care must be exercised during handling/repair of these items. Use electrostatic discharge (BSD) precautionary procedures.

GIVE CLEANERS/CHEMICALS SPECIAL CARE

Keep cleaners in approved safety containers and in minimum quantities. Some cleaners/chemicals may have an effect on skin, eyes, and respiratory tract. Observe manufacturer’s WARNING label and current safety directives. Use only in authorized areas. Discard soiled cleaning cloths into safety cans.

S1

USE SAFETY-APPROVED EQUIPMENT

When cleaners and primers are being applied, use approved explosion-prooflights, blowers, and other equipment. Ensure that firefighting equipment is readily available and in working order.

OBSERVE PRESSURE SYSTEM SAFETY PRECAUTIONS

Pressure system safety precautions apply to all ranges of pressure. Care must be taken during testing to ensure that all test connections are proper and tight prior to applying pressure to the test setup; all system components must be compatible with pressure applied. Use of compressed air can create an environment of propellent foreign particles. Air pressure shall be reduced to less than 30 psi and used with effective chip guarding and personal protective equipment.

WEAR PERSONAL PROTECTIVE EQUIPMENT

Wear protective clothing/equipment (gloves, apron, eye protection, etc.) approved for the materials, procedures, and tools being used. Contact supervisor for guidance. If necessary, the bioenvironmental engineer of the base safety office should be contacted for guidance.

S2

CHAPTER 1

INTRODUCTION AND DESCRIPTION

1-1 SCOPE, warming pad. The wanning pad keeps the coffee hot until ready for serving. The coffee maker is equipped with an

"This manual is a combined operation and maintenance electric sensing probe, which automatically shuts off the manual with illustrated parts breakdown for the coffee flow of water to me coffee maker when the wffee server maker, part number 50405-200, manufactured by Nordskog has reached the controlled amount of coffee.

Industries, Inc., 16000 Strathem Street, Van Nuys, California 91406. A three-quarter view ofthe coffee maker 1-4 CAPABILITIES AND FEATURES.

and rail assembly is provided in figure 1-1.

The coffee maker will provide 48 ounces of drip-brewed coffee in a 3 to 4 minute time frame. Hot and cold water

) .^ GENERAL. ls ^Bil^le from a spigot mounted on the coffee maker.

The coffee maker assembly is made up of a rail assembly, 1 "5 LEADING PARTICULARS.

P/N 78259-103, and the coffee maker, P/N 50405-200. The rail assembly is permanently mounted in the galley and the The ^"S particulars of the coffee maker are listed in electrical and water supplies are connected to the rail assembly. The coffee maker slides into the rail assembly and when fully inserted makes the water and electrical 1-6 ELECTROSTATIC DISCHARGE SENSI-connections. A rail lock is provided to secure the coffee TIVE (ESDS) EXPLANATION.

maker to the rail assembly.

This manual contains procedures for removing, replacing, 1 -3 DESCRIPTION, and adjusting components that are Electrostatic Discharge

Sensitive (ESDS). Paragraphs that address handling or

The coffee maker heats water to a preset temperature and maintenance which could damage ESDS components are injects a controlled amount into the brew head chamber. The identified by the ESDS symbol (^ and a CAUTION prior water then passes through a coffee bag which has been to the actual procedure. Each procedure is marked with the manually placed into the brew head chamber. Freshly letters (ESD) following the paragraph number and prior to brewed coffee is then dispensed directly into the coffee the paragraph title.

server, which has been set below the brew head on the

Table 1-1. Leading Particulars

Weight 13.25 pounds (empty)

Height 12 inches

Width .6.25 inches

Depth 14 inches

Water temperature at spigot 193 +/- 3 F Coffee server temperature 145 Minimum

Brew cycle .3.5 minutes (+/- 30 seconds with 28 psi inlet water pressure)

3.8 minutes (+/- 30 seconds with 23 psi inlet water pressure)

4.2 minutes (+/- 30 seconds with 20 psi inlet water pressure)

Power requirements .. 115/200 Vac, 3-phase, 400 Hz, 2825 watts

1-1

Figure 1-1. Coffee Maker and Rail Assembly

1-2

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2-1 GENERAL. 2-2 CONSUMABLE MATERIALS.

While it is not necessary to have special tools for the For a list of consumable items, refer to table 2-2.

installation, repair, and maintenance of this unit, time will be saved and damage will be less likely if the following tools are available. (Refer to table 2-1.) These tools and their uses are illustrated in chapter 5. Equivalent items may be used if the recommended tool/test equipment is not available.

Table 2-1, Special Tools and Test Equipment

Tool/Equipment Figure Number CAGE Number ___Nomenclature Use and Application

B99-007 81978 5-5 Valve sleeve tool Sleeve from valve disassembly

EAO-02-905 61706 5-1 Pincers Lens removal

EAO-02-906 61706 5-1 Lamp holder switch Lamp removal and replacement

3378 5-1 Installation tool Switch removal and replacement

3379 99212 Test box Testing PC board

8502-25 05668 Thermometer Testing brew head water temperature

18201502 05167 0-100 psi Pressure Gage Testing pressure relief valve

10008 83284 5-4 Heat Gun Shrink tubing

Table 2-2. Consumable Materials

Nomenclature Specification Part Number/CAGE

Black silicone rubber______ RTV732/02988

Insulating compound, elect, (heat sink) 10-8109/72653

Tape, antiseizing MIL-T-27730 P5025-1/81755

Vinegar___________________ 00754/73137____

2-1/(2-2 blank)

CHAPTER 3

PREPARATION FOR USE AND SHIPMENT

3-1 PREPARATION FOR USE. 3-2 PREPARATION FOR STORAGE OR

SHIPMENT.

a. Remove coffee maker from shipping container and a. Remove coffee maker from rail assembly by check for any damage; check that all removable unlocking rail lock (rotating upward) and pulling components (i.e., brew tray, coffee server, etc.) outward on coffee maker.

are included. Save shipping container for future use. b. Drain all liquid from coffee maker by opening drain valve.

b. Remove protective covers from electrical and water connectors and any shipping tags and plastic bags c. Wipe all components with a clean, dry cloth.

from the coffee maker.

d. Install protective covers over electrical and water

c. Position the rail lock lever to the up position and connectors.

slide the coffee maker into the rail assembly and lock in place, e. Put the coffee maker in its original shipping container for storage or pack unit for shipment in

d. Close drain valve if open. accordance with MIL-STD-2073-1.

e. Open water shut-off valve from water supply to allow water to enter coffee maker.

f. Press ON/OFF switch to ON. Press BREW switch to allow water to enter the brew chamber and the coffee server.

g. Turn off power switch and empty coffee server.

The unit is ready for use.

3-1/(3-2 blank)

CHAPTER 4

OPERATION INSTRUCTIONS

4-1 THEORY OF OPERATION, of the coffee bag to ensure that it fits into the brew tray.

Electrical power of 115/200 Vac, 3-phase, 400 Hz and pressurized water of 28 +/- 4 psi are provided from the d- Place the empty coffee server (4) on the wanning aircraft power sources to the connectors on the coffee maker psd (5) and ensure the sensing probe (6) falls into rail assembly mounted in the galley. When the coffee opening of the coffee server.

maker is slid in and locked to the rail assembly, electrical and water connections are made. Electrical power to the NOTE heating elements is controlled through a low-water probe in the coffee maker water tank. When the coffee maker water R is essential that the sensing probe fall into tank is full. the coffee maker probe completes a circuit to the coffee server, as this cuts off the water the power switch, which, when pushed, illuminates, and supply when the server is full.

completes a circuit to a relay. This relay in turn closes and completes the three-phase circuit to the water heating e- Slide the brew tray (3) with the coffee grounds into elements and makes a potential power source to the the brew chamber and press the brew tray and warming pad. When the brew switch is pushed, the light coffee server retaining lever (2) down.

illuminates. When the water is at the desired temperature (193 +/- 3 F), water will flow through the brew head and f- Depress the brew switch (7) and the warming pad empty into the brew server. When the water level in the switch (8). The coffee will brew when the water server reaches the sensing probes hanging in the coffee is at the correct temperature and will shut off server, the brew switch is deactivated, and the brew cycle automatically when the coffee is brewed. The stops. If the hot water switch is pressed during the brew warming pad will remain on to keep the coffee hot cycle, the cycle will stop and will begin again when the hot ""til served. When the coffee server is removed water switch is released and the water tank temperature or empty, turn off the warming pad switch (8).

reaches 193 F. The warming pad is turned on with the warming pad switch. The power to the warming pad will g. After each brew cycle, empty and rinse the coffee remain on until the switch is deactivated or the power switch grounds from the brew tray.

is turned off.

h. If cold water is required, hold container under

4-2 OPERATING INSTRUCTIONS. (See ^S01 (9> and P"^ and hold (:old water switch figure 4-1 ) (^) unt1^ deslred amount of water is in the container.

NOTE

n , Abbreviated operating instructions are printed L \ \ ^’^^^^^^.^^^k. .^.

on the front control panel of the coffee \\-^^ :^^^^^^il

a. Press power switch (1) on left-hand side of the K^"^^^^^L-s^^’^ ’VM control panel. The switch should illuminate, -^ >^-^^^^ * ;^ indicating power is applied to the coffee maker and / 1^^^ ^7> ’^jl water is being heated. 3 ^^^^ff ’’^K -\

b. Remove brew tray and coffee server by raising 0-- ’^7/7^^O^l^^ retaining lever (2) and pulling brew tray (3) and ^.L/"-^/^(R) ^1^ ^ coffee server (4) outward. <^^ 7 ’\ ’^\- Jf^

c. Gently pat or fluff a new coffee bag to loosen / ^^:;;;:;:^’^ .^\^^ coffee grounds. Place the coffee bag into the brew 4 ^^’’^’^’^^t tray with the seam downward and running from front to rear. Slightly turn up the ends and sides Figure d. Coffee Maker Operation

4-1

i. If hot water is required, hold container under b. If access to water source valve is not possible, spigot (9) and press and hold hot water switch (11) unlock rail lock (2) and pull coffee maker (3) out until desired amount of water is in container, of rail assembly (4) approximately 2 inches. This will disconnect the water connection between the NOTE rail assembly and the coffee maker. Drain water from the coffee maker by opening valve (1) and When hot water is taken from the spigot allowing water to drain into drain cavity under rail during the brew cycle, brewing will stop and assembly.

will not start again until the water is at the correct temperature. NOTE

j. When operation of the coffee maker is completed, Do not reconnect coffee maker to rail the following procedural steps should be assembly until ready for use. The coffee accomplished: maker will fill automatically when connected to the water supply.

(1) Empty and rinse brew tray (3).

(2) Empty any leftover coffee and rinse coffee -sec-.

server (4). ^^"^^^^^^^(3) Turn off wanning pad switch (8) and power ,-s?- ^^^^^^aM^switch (1). r^s.. ^^ ^21 -^’3

(4) Install brew tray (3) and coffee server (4) ^/ ^^^^’ ^ ^W and press retaining lever (2) down. :::fc^^^^*^ ^^’ i-affi f\

4-3 COLD WEATHER PROCEDURES. (See a-’^^- -^-^figure 4-2.) ./-’ !s^ ) ^^yV^^ ’<^’’wf

CAUTION ^^, "^?^^ ^ V^’^^’^^

If freezing temperatures are expected and the ^^-’3"’^*^^~^’--^’^^^^’’ coffee maker is not to be used, the coffee ""S^^""

^Bl^ maker water system must be drained to prevent damage by freezing.

Figure 4-2. Coffee Maker Draining

a. If freezing temperatures are expected, close off valve from water source and drain coffee maker by opening drain valve (1).

4-2

4-4 CONTROLS AND INDICATORS. (See figure 4-3.)

Control/Indicator Function

POWER SWITCH (1) Turns power on and off to coffee maker. Turning off will stop brewing process.

BREW SWITCH (2) Turns brewing process on. Process will remain on until coffee reaches the sensing probes or the power switch (1) is turned off.

WARMING PAD SWITCH (3) Turns wanning pad on and off. Will remain on until switch is turned off. If power switch (1) is turned off and wanning pad switch (3) is on, the switch will remain on but inactive.

HOT WATER SWITCH (4) When pushed and held, will provide hot water from spigot (12).

COLD WATER SWITCH (5) When pushed and held, will provide cold water from spigot (12).

COFFEE LEVEL SENSING PROBE (6) Shuts off brewing cycle when coffee level in coffee server reaches sensing probe.

RAIL LOCK (7) Locks coffee maker into coffee maker rails.

DRAIN VALVE (8) Used to drain water from coffee maker.

RETAINING LEVER (9) Down position locks brew tray and coffee server in place. Up position unlocks.

BREWING TRAY (10) Holds coffee bag in place during brewing process.

WARMING PAD (11) Keeps coffee warm after brewing.

SPIGOT (12) Outlet for hot or cold water.

4 5

Figure 4-3. Coffee Maker Controls and Indicators

4-3/(4-4 blank)

CHAPTER 5

MAINTENANCE INSTRUCTIONS

5-1 GENERAL REQUIREMENTS. When temperature reaches 193 P, turn the wanner pad switch on.

In order to perform the operational checkout procedures, the cleaning procedures, and the test procedures, a shop h- During brew cycle, press hot water switch. Brew environment with the following will be required: ^^ shmld ^P aad hot water should flow from spigot. Let hot water flow until heaters come on;

a. A coffee maker rail assembly (P/N78259-I03) after hot water now ^P8’ brew cycle should start mounted on a test functional work bench. ^am when the water reaches 193 F press cold water switch. Coldwater should flow from spigot,

b. A 115/200 Vac, 3-phase, 400-Hz power source and u should not affect the brew cycle with capability of reading source current on each phase L ^er t^u’e(R) ^rew ^l(R)3 wltn water at 193 + 3 F, place coffee bag in the brew head and press BREW

c. A 28 +/- 4 psi water source with an in-line shutoff switch. At 28 psi, in 3 minutes 30 seconds +/- 30 valve, flowmeter, and a supply tank that has the seconds, 48 ounces +/- 3 ounces of coffee should feature of being easily emptied and refilled with brew- P01 temperature should be a minimum of water or vinegar. ^^

d. Containers capable of holding vinegar for cleaning 5-3 INSPECTION AND PREVENTIVE parts. MAIN- TENANCE.

!5’2 OPERATIONAL CHECKOUT. 5-4 General. A preliminary cleaning (paragraph 5-5) before initial inspection will facilitate location of obvious

a. Turn the in-line water valve to the closed position, defects. Visually inspect working parts for cracks under strong light and magnification. Inspect structure for

b. Install coffee maker onto rail assembly that is distortion, corrosion, crossed or stripped threads, and mounted on a test function work bench, excessive wear that might impair the function of equipment.

c. With coffee maker water tank empty, turn the 5.5 Cleaning. The coffee maker should be completely power switch on. There should be no amperage cleaned every 1000 operating hours.

shown on ammeters for each phase of power.

a. Drain coffee maker completely by removing from

d. Open in-line water valve. After flow has started rail assembly and opening drain valve (8, figure 4-and the coffee maker water tank has filled, observe 3). Remove coffee maker to shop environment.

that heater elements energize. A0 8.0 +/- 0.5 amp; B0 7.0 +/- 0.5 amp; C0 7.0 +/- 0.5 b. Clean coffee maker external areas with a damp amp (with wanning pad oa). cloth to remove coffee spills, dust, etc.

e. Place a coffee server on the warming pad and c. Using the shop environment work bench as check to see that the sensing probe is inside the described in paragraph 5-1, empty the water supply server. Move the retaining lever to the locked tank and turn electrical power to the rail assembly position. OQ

f. Press BREW switch. When flow starts, check d. Insert coffee maker into rail assembly mounted on temperature by placing a thermometer directly into work bench and lock in place.

the flow of water below the brew head. Water temperature should be 193 +/- 3 P. Temperature e. Pill water supply tank on work bench with white is adjusted by a trim-pot located on the printed distilled vinegar.

circuit (PC) board (paragraph 5-12c).

f. Turn water supply tank in-line valve and the water

5-1 pump switch to the on position to allow the coffee evidence of arcing or flashover at pin insert maker to fill with distilled vinegar, insulation.

g. Follow applicable steps outlined in operating in- d. Check terminal strip for cracked insulation and structions (paragraph 4-2); allow vinegar to loose terminals.

circulate through the system. After one pot of vinegar has been brewed, shut off electrical power e. Check terminal strip cover for cracks.

and allow vinegar to stand in system for about 12 hours, f. Check open- and closed-position circuit function with ohmmeter at switch terminals. Check for

h. Drain vinegar from water supply tank and fill with evidence of arcing or flashover.

water.

g. Check to see that the coffee server sensing probe

i. After the 12-hour period, turn the electrical power is free of dirt or oils which may impair its to on. Following the appropriate operating function.

procedures in paragraph 4-2, circulate water through the coffee maker until all traces of vinegar 5-7 Plumbing.

are gone. Turn off all electrical power.

a. Check tubing for leakage and flattening; check for

CAUTION crimped, split, loose, or worn terminal ends.

Do not immerse coffee maker in water, b. Check tank assembly for leaks, deterioration, or

Damage to electrical components will result, cracks.

j. Wash coffee server and brew tray in warm water, c. Check for leaks and the quality of the sealing around the edges of the warming pad. If seal is

k. Using a damp cloth, clean the coffee server cavity, leaking or has become unacceptable, clean and the warming pad, the brew tray cavity, and the apply a new coat of RTV732 black silicone rubber sensing probe of any coffee residue or dirt. to the edges.

1. Perform the operational checkout of the coffee 5-8 TROUBLESHOOTING.

maker per paragraph 5-2.

a. Troubleshooting procedures can be performed in

m. Return the coffee maker to its operating either the Air Transportable Galley Lavatory environment. (ATGL) or in the shop environment as described in paragraph 5-1.

5-6 Electrical.

b. Assure that the water supply tank has water and,

a. Remove coffee maker from rail assembly, with normal voltage applied, actuate all necessary switches, circuit breakers, and the water supply

b. Inspect electrical wiring and connection points for pump in the ATGL.

damage, deteriorated insulation, and loose wires.

c. Table 5-1 lists symptom, probable cause, and

c. Check coffee maker electrical connector for corrective action for troubleshooting procedures.

loose,bent, or broken pins; deformed shells; and

Table 5-1. Troubleshooting

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Coffee maker fails to operate Open circuit breaker on top of coffee Reset circuit breaker (para. 5-13).

when power switch is pushed, maker

Thermistors Replace thermistor (para. 5-19).

Low-water probe Clean or replace (para. 5-20).

5-2

Table 5-7. Troubleshooting Continued

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Coffee maker fails to operate Power switch Replace switch (para. 5-11).

when power switch is pushed continued Relay Replace relay (para. 5-31).

PC board Replace PC board (para. 5-12).

No water flow to coffee maker Low water supply Fill tank.

Coffee maker improperly installed on Install coffee maker properly onto rail.

rail assy

Flow-control valve Repair or replace (para. 5-18).

Line plugged Isolate and clear.

Sensing probe improperly placed Hang in coffer server.

Slow coffee server fill Clogged restrictor Clean (para. 5-22).

Coffee server overflows Probe dirty Clean and check contacts.

Coffee not hot enough PC board Adjust, repair, or replace (para. 5-12).

Heating element Replace (para. 5-23).

Warming pad element Replace (para. 5-14).

Water leaks through brew head Brew electrical valve Clean, repair, or replace (para. 5-18).

when coffee maker is turned off

Hot water leaks from spigot Center electrical valve Clean, repair, or replace (para. 5-18).

Cold water leaks from spigot Bottom electrical valve Clean, repair, or replace (para. 5-18).

Water leaks continuously from Pressure relief valve Clean or replace (para. 5-16).

bottom of coffee maker

Auto-vent valve Replace (para, 5-17).

5-9 REPAIR, a. Removal.

/, (1) Remove lens (1) from switch assembly (2)5-10 General. The following paragraphs describe the v by inserting special tool P/N EAO-02-905, removal and installation procedures for components that are , or equiv-alent, in grooves at back of plastic to be removed and replaced during the repair cycle. When lens and pull forward.

applicable, paragraphs will cover the repair, cleaning, inspection, and testing of the components.

(2) Remove lamp from switch by pressing special tool EAO-02-906, or equivalent, 5-11 Push Button Switch Replacement. (See figure over bulb and pulling outward.

5-3

^\ ^^^^$^^^^^11 NORDSKOQ K^}’’’’’

^C ’"> ^^^^fi P/N3378--~^^ 4

A^ //^^^ ^^1^ ^-^-^’-^^^^s ^> 2

/// fci^%^ ^ ^^^ ^~ GROOVE (OVERCOME

^^ -^___ ^^’^ /^ ----’,5, SLIGHT PRESSURE)

\^^^^ ^--" ^ ^^r REPLACEMENT LAMP

VIEW A

Figure 5-1. Coffee Maker Push Button Switch Replacement

CAUTION b. Installation.

The PC board under the cover has BSD-rAiiTirM sensitive components. Use electrostatic discharge cautions to prevent damage to PC board.

When soldering wires to switch assembly,

(3) Gain access to back side of switch assembly prevent soldering iron temperature from by removing two screws and washers from exceeding 280 C (536 F), and accomplish top cover (3) and remove cover, soldering within 4 seconds. High temperatures and long duration of soldering may damage

(4) (ESD) Remove PC board per paragraph 5- switch.

12a.

(1) Assure nut (4) is in position around wires

(5) Using 11/16 inch open-end wrench or and using tag information, solder wires to special tool P/N 3378 on front of switch switch.

assembly (2) and holding nut (4) by hand, rotate wrench counterclockwise from 12 (2) Slide switch (2) into position; hold with o’clock to the 11 o’clock position to loosen wrench at 11 o’clock position and hand-the nut. Use fingers to remove the nut. tighten nut (4). Hold nut and turn wrench clockwise until switch is at 12 o’clock

(6) Pull switch assembly outward to gain access position.

to the electrical leads.

(3) Install lamp by positioning bulb installation

(7) Tag and unsolder leads from switch tool and pressing inward.

assembly.

(4) Position plastic cover over switch.

5-4

(5) (BSD) Install PC board per paragraph 5-12b. (3) Adjust the variable resistor R18 located on the PC board above the part number. Turn

(6) (BSD) Install top cover on coffee maker, clockwise to raise the temperature and counterclockwise to lower the temperature.

5-12 (ESD) Printed Circuit Board Replacement. (See One quarter turn changes the temperature figure 5-2.) approximately 30 degrees. The final temperature should be 193 +/- 3 F. Allow CAUTION the heating elements to cycle at least three times between each adjustment to allow The printed circuit board has ESD-sensitive temperature to stabilize.

components. Use electrostatic discharge pre-cautions to prevent damage to the printed (4) Install top cover (3) on coffee maker.

circuit board.

5-13 Circuit Breaker Replacement. (See figure 5-2.)

a. Removal.

a. Removal.

(1) Remove two screws (1) and washers (2) and lift top cover (3) off of coffee maker. (1) Remove top cover (2) from coffee maker per paragraph 5-12a.

(2) Remove two screws and washers (4) securing PC board (5) to coffee maker. (2) Remove PC board per paragraph 5-12a.

(3) Tag and disconnect wires from circuit

(3) Grasp PC board by the forward and rear breaker (6).

edge and slide left out of connector.

b. Installation. (4) Remove retaining nut and washer and remove circuit breaker from bracket.

(1) Position PC board (5) in connector and slide inward, b. Installation.

(2) Install two screws and washers (4). (1) Position circuit breaker in bracket and install nut and washer.

(3) Position coffee maker top cover (3) and install two washers (2) and screws (1). (2) Using tag information, connect wires to circuit breaker.

c. Adjusting. Adjusting the PC board consists of tuning the temperature control variable resistor. The (3) Install PC board per paragraph 5-12b.

temperature control should not be changed unless absolutely necessary. It has been factory tested and set to operate at (4) Position top cover on coffee maker and 193 +/- 3 "F. If the PC board has been replaced, the install screws.

temperature control may have to be adjusted as follows:

5-14 Warming Pad Heating Element Replacement.

(1) With the top cover (3) removed to expose (See figure 5-3.)

the PC board, turn the coffee maker on and allow the unit to operate through at least two a. Removal.

brew cycles to allow the temperature of all components to stabilize. (1) Remove screw (1), nut (2), and washer (3) from heating element (4).

(2) Determine the liquid temperature by placing a thermometer directly into the flow of (2) Remove screw (6) and nut (7). Remove water below the brew head. Record the clamp and drain line (8) as a unit from highest reading at the end of the cycle, heating pad.

5-5

(3) Trace wires from heating element (4) to 5-15 Tubing Replacement.

terminal strip (5).

a. Removal.

(4) Disconnect heating element wires from terminal posts 5 and 6. (1) Using a sharp knife or razor, cut tube on the side the length of the hose end fitting.

?-----J (2) Pull tubing from hose fitting.

/-’ ^’^’^Y \> b- Installation. (See figure 5-4 for tube routing.)

A^ ^^ NOTE

’^^^’^saSfSjS^ ^ tubes are removed for reasons other than

^^^^^^^^^^’’ being clogged, the tube may be reused.

^^^^’ ’^^^^^^li B (z) Obtain a piece of tubing the correct length.

..,-E^^^^^I^^^^ ’’HI ^ Cut end of tubing squarely.

^^’^--^^^feT’ * ^K ^ Using a 1/8-inch to 3/8-inch tapered reamer, y^s;^ ^7> ^Kl ^ ream out the inside of the tube end until the

^^rW * \^~ ID is 0.187 +/- .005 inch (3/16 inch).

/y’ y%=as \^(^\ L^* W Clean all chips from inside the tube and

^?^’ flush with water.

i^_ Y^^ .^^ ^) Slightly heat the end of the tube with a heat ’^. ^S^^ /-’ gun and slide onto fitting.

^-^^^ 5-16 Pressure Relief Valve Replacement. (See figure 5-4.)

Figure 5-2. Coffee Maker PC Board Removal a. Removal.

b. Installation. (1) Remove tube (1) per paragraph 5-15a.

(1) Position drain line (8) and clamp on heating (2) Remove pressure relief valve (2) by pad (4). Install screw (6) and nut (7). unscrewing from fitting (3).

(2) Spread a small amount of black silicone (3) Remove fitting (4) from relief valve.

rubber (RTV732) around screw hole in coffee maker and around hole in heating b. Cleaning. The following procedures are required element, ooly ^hen water is leaking from the valve and a new valve is not available.

(3) Install screw (1) through the holes in both the coffee maker and the heating element (4). Install washer (3) and nut (2). (1) O^861^16 ^Ive and wash parts with water. If water does not remove all particles, soak parts in vinegar for about 12,

(4) Route wires to terminal strip (5) and install i, one wire on terminal lug 5 and one on terminal lug 6. Install terminal board cover.

(2) Reassemble valve.

5-6

^^.s?’- ^^^ VIEWLOOK1NQ

>C"^^<t.^ AT BOTTOM OF r ’\(^^ COFFEE MAKER

Figure 5-3. Coffee Maker Warming Pad Removal

(3) Check valve with pressure. Valve should b. Installation.

open at 65 +/- 5 psig. If valve does not open or opens sooner than this pressure, replace (1) Apply antiseizing tape to threads of new valve, vent valve assembly (7).

c. Installation. (See figure 5-4.) (2) Screw vent valve assembly into water tank (8).

(1) Apply antiseizing tape to threads of fittings

(3) and (4). (^) Apply antiseizing tape to threads of hose fitting (6) and install hose fitting into vent

(2) Screw fitting (4) into the end that the arrow valve (7)-points to on the relief valve (2).

(4) Install tube (5) per paragraph 5-15b.

(3) Screw other end of relief valve onto fitting /3) 5-18 Flow-Control Valve Replacement. (See figure

5-4.) Three flow control valves (9, 10, and 11) are

(4) Install tube (1) onto fitting (4) per paragraph colmected togetlle^ with "PP168 (12) tomake an assembly.

SISh repair or replace any one of the three control valves (brew, hot, or cold) the complete group (the assembly) must be removed

5-17 Auto-Vent Valve Replacement. (See figure 5-

^ a. Removal.

a. Rempval. (i) Cut tie-wraps from wire bundle aft of the flow control valves.

(1) Remove tube (5) per paragraph 5-15a.

(2) Tag and remove black wire from studs on

(2) Remove hose fitting (6) from vent valve terminal strip as follows: Brew valve wires assembly (7). go to studs 8 and 12; hot water valve wires go to studs 8 and 13. Cold water valve

(3) Remove vent valve assembly (7) from water wires go to studs 14 and DC GND. (See tank (8). figure 6-1 for other details.)

(3) Remove tubes (13, 14, and 15) per paragraph 5-15a.

5-7 soaking in, vinegar for about 12 hours and rinse with water.

3 I 4

\ \^ / d. Assembly.

BREWHEAo N^ \_A 1[^1’1^^ H ^ ^"^ new ^""S ^) an^ plunger (5) into

/-IBI^^^T^S^ ^ ^f^ -^" )) plunger housing (2).<-s^BREw( ^^^^" X X "-^/ l4--’HOTn-|S^ .^x^ \ (2) Install new packing (7) into body (8).

SPIGOT^^s^^^^^lO ff \ \.^12-^coLDT^^^ /f 5 ^ Insta11 plunger housing (2) into body (8).

.^ v^^^, (I ^8 ^tse tool (4) and a wrench to tighten.

/ ft I ^0^ (4) Slide coil (3) onto plunger housing (2) and

^ l|j^^ 1:ILL install nut (1).

ST^’^ ^ ’^asS^ily (5) Assemble the valve group by screwing cpSy^’^^’’^^ valves into nipples (12, figure 5-4).

Figure 5-4. Coffee Maker Plumbing Installation 5 mi’\

(4) Working from coffee server cavity, remove 2 ^’A.-)^^^ two screws and washers from back wall \ {S^{^\ ^\.

holding the flow control valves to the wall. \ ^^i-^^ \ ^

(5) Pull the flow-control valves assembly off \ / .)

and out. The spigot tube should slide out of V^.J^ ^-^ DO NOT SQUEEZE the spigot, ^n

b. Disassembly. The three valves should be separated if a valve in the group needs to be replaced. To ^’T^?! If separate, unscrew valve from nipple (12), then remove / ’~"^ B99-007 11--I remaining nipple. Install new valve by reversing procedure. / //^i VALVE SLEEVE / ^\ kl^^001 fH/ c- Repair. (See figure 5-5.) Repair consists of IT^SC ^^- ^^^X cleaning or replacement of plunger, spring, and 0-ring. /^"^^s.^ ^^ 7/^\ These parts can be obtained in repair kit P/N B60-S002. f ^i^^ l:({^/ ^’4 This kit also includes spanner nut tool P/N B99-007. c--^f /^\

(1) Remove nut (1) from plunger housing (2) /’ ^"^i. ^^^and remove coil (3). / ^\^

(2) Position tool (4) on plunger housing (2) as fn^ //)n shown; using wrench, turn counterclockwise ^U"^^ ^ \^/to remove. ^\\

(3) Remove and discard plunger (5) and spring

(6) from plunger housing (2).

Figure 5-6. Flow-Control Valve Repair

(4) Remove and discard packing (7) from body

(8).

(5) Clean plunger housing (2) and body (8) by

5-8

e. Installation. (See figure 5-4.) checking resistance. Check resistance for (1) by checking between pin 1 of PC board connector (3) and DC GND stud

(1) Position the flow-control valve assembly so (4). Check resistance for (2) by checking between pin 16 the hose to the spigot will go through the of PC board connector (3) and DC GND stud (4). Replace bulkhead and slide into the spigot, the thermistor that has no resistance.

(2) Working from inside the coffee server a. Removal.

cavity, install the two screws and washers that hold the flow-control valve assembly to (1) Remove printed circuit board per paragraph the coffee maker. 5-12a.

(3) Install tubes (13, 14, and 15) per paragraph (2) Cut tie-wrap on wire bundle from 5-15b. thermistors to terminal board (8).

(4) Install wires on stud from bottom of terminal (3) To remove thermistor (1), disconnect black board and ground stud as tagged during wire from terminal 10 (fourth from top) on removal. (See figure 6-1.) terminal board (8). To remove thermistor (2), remove black wire from terminal 11

(5) Tie-wrap wires as necessary, (fifth from top) on terminal board (8).

(4) Remove the appropriate ground wire from the DC GND terminal.

(5) Pull appropriate wire from wire bundle and, J_ ^"^"".-i ^-i. using a wrench, unscrew and remove the

/--4 appropriate thermistor (1 or 2).

a

3~- ^ (R) b. Installation.

1 ^QY^’~5\’ ^ Apply antiseizing tape to threads of | i T,- --"’^ thermistor and screw into water tank.

jl (2) Route wires along wire bundle to the

’" y ^ appropriate terminal (10 for thermistor (1)

31HMWU AMIIXW^

{ and 11 for thermistor (2)). The other wire

3^’ivn ^NIAaqyJ will go to the DC GND terminal.

W \ /-I

HOT WATER ^\ TEMP CONTROL

OUTLETTO \\-^ r~\ i:^^i-\ 193 +/- 3 REF (3) Install tie-wraps around wire bundle.

BREWHEAD- -V-V V <&,

& FAUCET \ l^e REF. V ^ /-^ / WATER LEVEL (4) Install printed circuit board per paragraph 5-

J^~ ’2S’ ’-ML SENSINQ 12b.

8---^y/ ^r^Y^ PROBE REF.

/ \ / ^H1 2 5-20 Low-Water Probe Replacement. (See figure 5-

/ / S OVERHEAT SWITCH 6.)

AUTO VENT7 / OEF

REF. V

THERMOSTATS a. Removal.

VIEW LOOKING DOWN (1) Remove terminal cover from probe (5).

ON COFFEE MAKER

(2) Remove nut, washer, and electric wire.

Figure 5-6. Coffee Maker Repair

(3) Unscrew and remove probe (5) from water tank.

5-19 Thermistor Replacement. (See figure 5-6.)

Determine the thermistor (1) or (2) to be replaced by

5-9

b. Cleaning. Soak probe in vinegar for about 12 c. Installation.

hours; rinse with water.

(1) Apply antiseizing tape to threads of fitting

c. Installation. (7) and screw into brew head.

(1) Apply antiseizing tape to threads of probe (2) Install tube (6) per paragraph 5-15b.

and screw into water tank.

(3) Install printed circuit board per paragraph 5-

(2) Connect electric wire to terminal and install 12b.

nut and washer.

5-23 Heating Element Replacement. (See figure 5-

(3) Install terminal cover. 7.) Heating elements (1, 2, and 3) are all removed in the same manner. The only difference is the wire connections.

5-21 Thermostat Replacement. (See figure 5-6.)

Determine thermostat to be removed by performing a. Removal.

continuity check while coffee maker is cold. The thermostat with the open circuit should be replaced. (1) Tag and remove wires from heating element.

a- Removal. (2) Cut wire ties from bundle.

(1) Loosen the two clamps at the top of the (3) Loosen three clamps holding water tank to water tank; lift the three thermostats and bracket.

bracket out as an assembly.

(4) Slide water tank upward to gain access to

(2) Unsolder wires from thermostat to be heating elements.

replaced and lift from bracket.

(5) Using wrench, unscrew heating element

b. Installation, from water tank.

VIEW LOOKING AT

(1) Position new thermostat in bracket and COFFEE MAKER solder wires to thermostat.

(2) Apply heat sink compound to back sides of J thermostats and position in place on water | tank. H

(3) Tighten two clamps to hold in place on // .^-A ’^ / water tank. /f/-. / ^.^^ \\ /

5-22 Restrictor Valve Replacement. (See figure 5-6.) b/^ j^/

a. Removal. /^^__^^’ ^\

(1) Remove printed circuit board per paragraph (T qsp-a^g^^eJ|KT 5-12a /f- "^S "^^" v\%\

’’^--^J [’l^

(2) Remove tube (6) per paragraph 5-15a. || ^-^J^~^ II I) 3

(3) Remove fitting (7) by unscrewing. <^i^^ ^ ,^ lf8 ’i’ 11 ii I-"

b. Cleaning. Use a no. 63 drill bit and clean out small hole in fitting (7). Wash and blow through hole to 3 clear.

Figure 5-7. Heating Element Removal

5-10

b. Installation. p. Install electrical leads on ground terminal on bottom of tank.

(1) Apply antiseizing tape to threads of heating element and install in water tank. I- Inst(dl a11 ^"S S01^to water tank P^Pa^Ph

5-15b.

(2) Slide water tank into position and tighten 5.25 Probe Assembly Replacement. (See figure 5-8).

three clamps to secure.

a. Removal.

(3) Connect wires to heating element as

^ Remove printed circuit board per paragraph previously tagged.

5-24 Water Tank Replacement. (2) Unsolder wire from terminal 14 of printed circuit board connector.

a. Disconnect all tubes going to water tank per paragraph 5-15a. ^ cut ^^"P securing wire (1) in coffee server cavity.

b. Disconnect thermistors’ electrical wires per paragraph 5-19a. (4) Remove screw (5) securing cover plate (6) to brew chamber.

c. Disconnect low-water probe electrical wire per paragraph 5-20a. (5) Remove two screws (2) securing probe assembly (3) to coffee maker.

d. Remove thermostats per paragraph 5-21a.

e. Disconnect heating elements’ electrical wires per paragraph 5-23a.

OKIUTMO MITnjCTKM

f. Disconnect all ground wires from bottom of water t^^s^^^’c^i.^Sai?*"’’’Kt

g. Loosen clamps holding water tank onto bracket and v^^^^>..,^^^,w_^ slide water tank out of coffee maker. ^ NORDSKOG

h. Remove heating elements from old tank and install in new tank per paragraph 5-23. _______________J_

6^.

i. Remove thermistors from old tank and install in \ ^x^^i::]i^’^ new tank per paragraph 5-19. ^"2-" ^^(R)^^

j. Remove low-water probe from old tank and install ^ i_ ^^^-’-^^^in new tank per paragraph 5-20. ^^g ^ ^^"~- -^

k. Slide new water tank into position and tighten ___|| clamps. ,^T

1. Install electrical leads per paragraphs as follows: // 2 _^/

Heating element, 5-23b 7^ _______fr- 8

Low-water probe, 5-20c / TO DRAIN ^e}-~ 7 Thermistors, 5-19b 5 rCD -AW^-ly

m. Remove auto-vent valve from old tank and install in new tank per paragraph 5-17.

n. Remove pressure relief valve from old tank and install in new tank per paragraph 5-16.

o. Install thermostats per paragraph 5-21b, steps 2 and ^g^ g,g ^^ ^g, p^y Replacement

5-11

b. Installation, b. Installation.

(1) Route wire from new probe assembly (D position new drain valve (8) and install nut through grommet (4) in back side of coffee (7) ^ ^old y^ in p^e.

server cavity, up the side of the water tank, to the printed circuit board. (2) install tubes on drain valve per paragraph 5-

(2) Install probe assembly (3) by installing two screws (2).

5-27 Rail Lock Replacement.

(3) Install tie-wrap around wire to secure it in place, a. Removal.

(4) Install cover plate (6) and secure with screw

^ ^^^,^^ye of coffee maker securing the rail lock to coffee maker.

(5) Solder wire to printed circuit board terminal

14. (2) Using a knife, cut rubber sealing compound from edges of rail lock assembly and

(6) Install printed circuit board per paragraph 5- remove rail lock.

12b.

5-26 Drain Valve Replacement. (See figure 5-8.) b- Installatipn.

a. Removal. (1) Clean area of old rubber sealing compound.

(1) Remove tubes from drain valve (8) per ^) p^^^^^^^ ^^1paragraph 5-15a.

g^

(2) Working from inside coffee server cavity, loosen and remove nut (7) holding drain (3) Seal all of the edges that mate with the valve (8) in place coffee maker using black silicone rubber

(RTV732).

(3) Remove drain valve (8) from the underside of the coffee maker.

6 3^^^ 9 2 7 4

5 Figure 5-9. Brew Chamber Removal

5-12

b. Disassembly. (See figure 5-10.)

^^o |----3 (1) Remove restrictor valve (1) from brew head ’A<&-< cover (2).

2^^ ^t^ (C) .^^ (2) Remove fourteen screws (3) and nuts (4)

^^ ^^ securing cover (2) to brew head body.

^^/^,^^S>^ (3) Separate brew head body (5), cover (2), and

^^^ ^^si^ brew head bladder (6).

6--^^^si^^1 c’ c’ean’’"Q

^^ ^’\ ^^^ib? ^ Soak all parts in vinegar for about 12 hours.

^^^;^^^^^^ (2) Rinse all parts with water.

^^y^ \ WARNING""

Use of compressed air can create an Figure 5-10. Brew Head Assembly environment of propellant foreign particles.

Air pressure shall be reduced to less than 30 5-28 Brew Chamber Replacement. (See figure 5-9.) psi and used with effective chip guarding and personal protective equipment.

a. Removal.

(3) Clean out brew holes in bladder with air

(1) Remove printed circuit board per paragraph pressure.

5-12a.

(4) Clean out hole in restrictor valve with a

(2) Remove tube…