TechnicalOrder_Coffee_Maker_Rail_Assembly_5_20_24.pdf

TO 13B6-4-2

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED

PARTS BREAKDOWN

ORGANIZATIONAL AND INTERMEDIATE

COFFEE MAKER

PN 500-582

RAIL ASSEMBLY

PN 500-327-4

TIA Electric Company

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) (1 September 1995). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/WNZEBA.

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

12 JULY 2014 CHANGE 1 - 1 OCTOBER 2014

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

Dates of issue for original and changed pages are:

Original. . . . . . . .0 . . . . . . . 12 July 2014 Change . . . . . . . . 1 . . . . . 1 October 2014

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 68, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv Blank v - viii 1-1 - 1-2 2-1 2-2 Blank 3-1 3-2 Blank 4-1 4-2 - 4-3 4-4 Blank 5-1 - 5-19 5-20 5-21 - 5-23 5-24 Blank 6-1 - 6-12 6-13 Blank 6-14 - 6-15 6-16 6-17 Blank 6-18 - 6-22

FP-1

FP-2 Blank

TO 13B6-4-2

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

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.

* Zero in this column indicates an original page.

A Change 1 USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . iii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . iii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . v

SAFETY SUMMARY . . . . . . . . . . . . . . . . . vii

1 INTRODUCTION AND DESCRIPTION . . . . 1-1

1.1 CAPABILITIES AND

FEATURES. . . . . . . . . . . . . . . 1-1

1.2 LEADING PARTICULARS . . . . . . 1-1

1.3 ELECTROSTATIC DISCHARGE

SENSITIVE (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 . . . . . . . . . . . . . 4-2

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

5.1 GENERAL REQUIREMENTS. . . . 5-1

5.2 OPERATIONAL CHECKOUT . . . . 5-1

5.3 TEMPERATURE

CALIBRATION . . . . . . . . . . . . 5-5

5.4 INSPECTION AND PREVENTIVE

MAINTENANCE. . . . . . . . . . . 5-5

5.4.1 General. . . . . . . . . . . . . . . . . . . . 5-5

5.4.2 Cleaning . . . . . . . . . . . . . . . . . . . 5-5

Chapter Page

5.4.3 Electrical Inspection . . . . . . . . . . . 5-5

5.4.4 Plumbing . . . . . . . . . . . . . . . . . . 5-6

5.5 TROUBLESHOOTING. . . . . . . . . 5-6

5.6 REPAIR . . . . . . . . . . . . . . . . . . . 5-7

5.6.1 General. . . . . . . . . . . . . . . . . . . . 5-7

5.6.2 Switch Panel Assembly

Replacement . . . . . . . . . . . . . . 5-7

5.6.3 Printed Circuit Board

Replacement . . . . . . . . . . . . . . 5-8

5.6.4 Warming Pad Heating Element

Replacement . . . . . . . . . . . . . . 5-9

5.6.5 Tubing Replacement . . . . . . . . . . . 5-9

5.6.6 Pressure Relief Valve

Replacement . . . . . . . . . . . . . . 5-10

5.6.7 Vent Valve Replacement . . . . . . . . 5-10

5.6.8 Solenoid Valve Replacement . . . . . 5-12

5.6.9 Flow Restrictor Replacement . . . . . 5-13

5.6.10 Thermistor Replacement . . . . . . . . 5-13

5.6.11 Low-Water Probe Replacement. . . . 5-14

5.6.12 Secondary Overheat Thermostat

Reolacement . . . . . . . . . . . . . . 5-14

5.6.13 Heating Element Replacement . . . . 5-14

5.6.14 Primary Overheat Thermostat

Replacement . . . . . . . . . . . . . . 5-15

5.6.15 Brew Head Assembly

Replacement . . . . . . . . . . . . . . 5-16

5.6.16 Water Tank Replacement . . . . . . . . 5-17

5.6.17 Probe Replacement . . . . . . . . . . . . 5-20

5.6.18 Drain Valve Replacement . . . . . . . 5-20

5.6.19 Rail Lock Replacement . . . . . . . . . 5-20

5.6.20 Brew Tray and Pot Retainer

Replacement . . . . . . . . . . . . . . 5-20

5.6.21 Relay Replacement . . . . . . . . . . . . 5-21

5.6.22 Rail Assembly Repair . . . . . . . . . . 5-21

5.6.23 Water Connector Replacement . . . . 5-21

5.6.24 Electrical Connector

Replacement . . . . . . . . . . . . . . 5-21

6 ILLUSTRATED PARTS BREAKDOWN . . . . 6-1

SECTION I FOREWORD . . . . . . . . . . . . . . 6-1

6.1 INTRODUCTION . . . . . . . . . . . . 6-1

6.2 MODELS COVERED. . . . . . . . . . 6-1

6.3 FINDING PART NUMBERS, IL-

LUSTRATION,

DESCRIPTION . . . . . . . . . . . . 6-1

6.4 SIMILAR ASSEMBLIES . . . . . . . 6-1

6.5 SHEET NUMBER

EXPLANATION . . . . . . . . . . . 6-1

i

Chapter Page

6.6 USABLE ON CODES . . . . . . . . . 6-1

6.7 SOURCE, MAINTENANCE, AND

RECOVERABILITY (SMR)

CODES . . . . . . . . . . . . . . . . . 6-1

6.8 PARTS STANDARDIZATION . . . . 6-1

6.9 MANUFACTURER’S LIST. . . . . . 6-2

6.10 MAINTENANCE PARTS LIST

(MPL) . . . . . . . . . . . . . . . . . . 6-2

6.10.1 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 6-2

6.10.2 Part Number Column . . . . . . . . . . 6-2

6.10.2.1 Commercial Hardware . . . . . . . . . 6-2

6.10.2.2 Parts Not Illustrated . . . . . . . . . . . 6-2

6.10.2.3 Markings . . . . . . . . . . . . . . . . . . 6-2

6.10.2.4 Government Furnished Equipment

(GFE) and Contractor Furnished Equipment (CFE) Covered by Separate Manuals . . . . . . . . . . . 6-2

6.10.3 CAGE Column . . . . . . . . . . . . . . 6-2

Chapter Page

6.10.4 Description Column . . . . . . . . . . . 6-2

6.10.4.1 Indentation . . . . . . . . . . . . . . . . . 6-2

6.10.5 Units Per Assembly Column . . . . . 6-3

6.10.6 Usable on Code Column . . . . . . . . 6-3

6.10.7 Source, Maintenance, and Recover-

ability (SMR) Code Column . . . 6-3

6.11 NUMERICAL INDEX (NI) . . . . . . 6-3

6.11.1 Part Number Column . . . . . . . . . . 6-3

6.11.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 6-3

6.12 REFERENCE DESIGNATION. . . . 6-3

6.12.1 Reference Designator Column . . . . 6-3

6.12.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 6-3

SECTION II MAINTENANCE PARTS

LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

TO 13B6-4-2

TABLE OF CONTENTS - CONTINUED

ii

LIST OF ILLUSTRATIONS

Number PageTitle

1-1 Coffee Maker and Rail Assembly . . . . . . 1-2 4-1 Coffee Maker Operation . . . . . . . . . . . . 4-2 4-2 Coffee Maker Draining . . . . . . . . . . . . . 4-2 4-3 Coffee Maker Controls and Indicators . . . 4-3 5-1 Operational Checkout . . . . . . . . . . . . . . 5-3 5-2 Temperature Calibration. . . . . . . . . . . . . 5-4 5-3 Coffee Maker Push Button Switch

Replacement . . . . . . . . . . . . . . . . . . 5-7 5-4 Coffee Maker PC Board Removal . . . . . . 5-8 5-5 Coffee Warming Pad Removal . . . . . . . . 5-9 5-6 Coffee Maker Plumbing Installation. . . . . 5-11 5-7 Flow Control Valve Repair. . . . . . . . . . . 5-13 5-8 Coffee Maker Repair . . . . . . . . . . . . . . . 5-13 5-9 Heating Element Removal . . . . . . . . . . . 5-14

Number PageTitle

5-10 Brew Chamber Removal . . . . . . . . . . . . 5-15 5-11 Brew Head Assembly . . . . . . . . . . . . . . 5-16 5-12 Liquid Level Probe Replacement. . . . . . . 5-19 5-13 Relay Replacement . . . . . . . . . . . . . . . . 5-21 5-14 Rail Assembly Repair . . . . . . . . . . . . . . 5-23 6-1 Coffee Maker and Rail Assembly . . . . . . 6-7 6-2 Brew Head Assembly and Probe

Assembly . . . . . . . . . . . . . . . . . . . . 6-14 6-3 Lock Pin Assembly. . . . . . . . . . . . . . . . 6-16 6-4 Water Tank Assembly . . . . . . . . . . . . . . 6-18 6-5 Solenoid Valve Assembly. . . . . . . . . . . . 6-20 6-6 Water Inlet Manifold Assembly. . . . . . . . 6-21 6-7 Coffee Maker Rail Assembly . . . . . . . . . 6-22 FO-1 Coffee Maker Electrical Schematic . . . . . FP-1

LIST OF TABLES

Number PageTitle

1-1 Leading Particulars . . . . . . . . . . . . . . . . 1-1 2-1 Special Tools and Test Equipment . . . . . . 2-1 2-2 Consumable Materials . . . . . . . . . . . . . . 2-1

Number PageTitle

4-1 Controls and Indicators . . . . . . . . . . . . . 4-3 5-1 Troubleshooting . . . . . . . . . . . . . . . . . . 5-6 iii/(iv blank)

FOREWORD

1 PURPOSE.

The coffee maker assembly is made up of a Rail Assembly, PN 500-327-4, and the Coffee Maker, PN 500-582. The rail assembly is permanently mounted in the galley and the elec-trical 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 connections. A rail lock is provided to secure the coffee maker to the rail assembly. The coffee maker heats water to a preset tempera-ture and injects a controlled amount into the brew head chamber. The water then passes through a coffee bag which has been manually placed into the brew head chamber.

Freshly brewed coffee is then dispensed directly into the cof-fee server, which has been set below the brew head on the warming pad. The warming pad keeps the coffee hot until ready for serving. The coffee maker is equipped with a dual stainless steel probe system, which automatically shuts off the flow of water to the coffee maker when the coffee server has reached the controlled amount of coffee.

2 SCOPE.

This manual is a combined operation and maintenance manual with illustrated parts breakdown for the Coffee Maker, PN 500-582 and Rail Assembly, PN 500-327-4, manufactured by TIA Electric Company, 22 Audrey Place, Fairfield, NJ 07004. A three-quarter view of the coffee maker and rail assembly is provided in Figure 1-1.

3 SYMBOLS.

- A dash (-) before an index number denotes a part which is not illustrated.

* An asterisk (*) flush right of the part number denotes a marking that is to be requisitioned in accordance with DODI 5330.03_AFI 33- 395.

# A number sign (#) flush right of a part number indicates that detail parts are listed in a sepa-rate manual.

F The letter “F” before the figure number means “follows” and is used when an assembly or part has not been assigned an index number, and the figure and index number of the pre-ceding part has been used.

4 ABBREVIATIONS.

All abbreviations used in this manual are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents.

AF Air Force

AFTO Air Force Technical Order ALT Alternate AMP Ampere AP Attaching Parts AR As Required ASSY Assembly ATGL Air Transportable Galley Lavatory CAGE Commercial and Government Entity CFE Contractor Furnished Equipment DoD Department of Defense ESD Electrostatic Discharge ESDS Electrostatic Discharge Sensitive F Fahrenheit GAL Gallon GFE Government Furnished Equipment Hz Hertz I&S Interchangeability and Substitution

in. inch IPB Illustrated Parts Breakdown LB Pound LED Light-Emitting Diode LH Left Hand MIN Minute MPL Maintenance Parts List NHA Next Higher Assembly NI Numerical Index PN Part Number PC Printed Circuit PSI Pound-Force Per Square Inch RDI Reference Designator Index REF Reference RH Right Hand SMR Source, Maintenance, and Recoverability SYS System UOC Usable on Code VAC Volts Alternating Current W Watt

5 RELATED PUBLICATIONS.

The following publications contain information in support of this technical manual.

List of Related Publications

Number Title ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents v

List of Related Publications - Continued

Number Title DODI 5330.03_AFI 33-395 Document Automation and

Production Service

(DAPS)

TO 00-5-1-WA-1 Air Force Technical Order System

TO 00-25-195-WA-1 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Sys-tems, and Equipment

List of Related Publications - Continued

Number Title TO 00-25-234-WA-1 General Shop Practice Re-quirements for the Repair, Maintenance, and Test of Electrical Equipment

6 RECORD OF APPLICABLE TIME COMPLIANCE

TECHNICAL ORDERS (TCTOS).

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

None

7 HARDNESS CRITICAL ITEMS (HCI).

The HCI symbol ( ) establishes special re-quirements limiting changes and substitutions and that the specific parts listed must be used to ensure hardness is not degraded.

If included, items with nuclear survivability requirements are marked with the HCI symbol ( ). All changes to, or pro-posed substitutions of, HCIs must be approved by the ac-quiring activity.

8 ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) ITEMS.

All ESDS parts shall be handled in accordance with the ESDS device handling procedures in TO

00-25-234-WA-1.

If included, items containing ESDS parts are marked with the ESDS symbol ( ).

9 CHANGE RECOMMENDATIONS.

Recommendations proposing changes to this technical order shall be submitted on an AFTO Form 22 in accordance with TO 00-5-1-WA-1. Forward completed AFTO Form 22 to the Technical Order Management Agency (TOMA) at:

robins.ce.afto22@us.af.mil.

vi

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and/or chemical processes which may cause injury or death to personnel, or damage to equipment, if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any specific task, the WARNINGs, CAU- TIONs, and NOTEs included in that task shall be reviewed and understood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are considered essential to protection of personnel (WARNING) or equipment (CAU- TION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, CAUTION, or icon), a statement of the hazard, minimum precautions, and possible results if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are not essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending upon the information to be highlighted. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in in-jury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in dam-age to, or destruction of, equipment or loss of mis-sion effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

3 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 re-quirements.

4 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. Remove finger rings during all periods of maintenance.

5 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 dan-gerous voltage shall be trained in modem methods of resus-citation. Information and training sources may be obtained from the director of base medical services.

6 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 (ESD) precautionary procedures.

7 GIVE CLEANERS/CHEMICALS SPECIAL CARE.

Keep cleaners in approved safety containers and in mini-mum quantities. Some cleaners/chemicals may have an ef-fect on skin, eyes, and respiratory tract. Observe manufactur-er’s WARNING label and current safety directives. Use only in authorized areas. Discard soiled cleaning cloths into safety cans.

8 USE SAFETY-APPROVED EQUIPMENT.

When cleaners and primers are being applied, use approved explosion-proof lights, blowers, and other equipment. En-sure that fire fighting equipment is readily available and in working order.

vii

9 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 pres-sure to the test setup; all system components must be com-patible with pressure applied. Use of compressed air can cre-ate 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.

10 WEAR PERSONAL PROTECTIVE EQUIPMENT.

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

viii

CHAPTER 1

INTRODUCTION AND DESCRIPTION

1.1 CAPABILITIES AND FEATURES.

The coffee maker will provide 48 ounces of drip-brewed cof-fee in a 2 to 4 minute time frame. Hot and cold water are available from a spigot mounted on the coffee maker.

1.2 LEADING PARTICULARS.

The leading particulars of the coffee maker are listed in Table 1-1.

1.3 ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) EXPLANATION.

This manual contains procedures for removing, replacing, and adjusting components that are Electrostatic Discharge Sensitive (ESDS). Paragraphs that address handling or main-tenance which could damage ESDS components are identi-fied by the ESDS symbol and a CAUTION prior to the actual procedure. Each procedure is marked with the letters (ESD) following the paragraph number and prior to the para-graph title. Consult TO 00-25-234 for instructions.

Table 1-1. Leading Particulars

Item Specification Weight 13.50 pounds (LBS) (empty) Height 12 inch (in.)

Width 6.312 in.

Depth 14.50 in.

Water temperature at spigot 185 °Fahrenheit (F) Coffee server temperature 145 °F minimum Brew cycle 2 to 4 minutes

NOTE

Assuming 28 ±4 pounds-force per square inch (PSI) inlet water pressure.

Power requirements 115/200 volts alternating current (VAC), 3-phase, 400 Hertz (Hz), 2760 Watts (W)

1-1

Figure 1-1. Coffee Maker and Rail Assembly

1-2

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2.1 GENERAL.

While it is not necessary to have special tools for the instal-lation, repair, and maintenance of this unit, time will be saved and risk of damage will be less 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.

2.2 CONSUMABLE MATERIALS.

For a list of consumable items, refer to Table 2-2.

Table 2-1. Special Tools and Test Equipment

Tool/Equipment Number Cage Figure

Number Nomenclature Use And Application B99-007 81978 Figure 5-1 Spanner nut (valve sleeve tool) Disassemble sleeve from valve 3379 99212 Test box Test printed circuit (PC) board 8502-25 05668 Thermometer Test brew head water temperature 1-15-0305 57217 Pressure gauge, 0-100 Pounds-

Force Per Square Inch (PSI) Measure pressure in pressure relief valve 20B540 54932 Flowmeter gallon (GAL)/min-ute (MIN) Monitor water flow

LAA3-T 15566 Ammeter Measure current draw in the coffee maker

AN/PSM-4C 88058 Multimeter Check current/voltage during opera-tional checks and testing

Local purchase Magnifying glass, 10X Check working parts for cracks

Table 2-2. Consumable Materials

Nomenclature Specification Part Number/Cage Black silicone rubber MIL-R-46089C RTV732/71984 Insulating compound, elect. (heat sink) 10-8109/72653 Tape, antiseizing MIL-T-27730 P5025-1/81755 Vinegar, distilled, white Local Purchase Tie Wraps MS 17821-1-9/96906 Tubing, Plas-tic Tubing, Plastic ASTM D2846-93 Local Purchase

2-1/(2-2 blank)

CHAPTER 3

PREPARATION FOR USE AND SHIPMENT

3.1 PREPARATION FOR USE.

a. Remove coffee maker from shipping container and check for damage; check that all removable compo-nents (i.e., brew tray, coffee server, etc.) are included.

Save shipping container for future use.

b. Remove protective covers from electrical and water connectors and any shipping tags and plastic bags from the coffee maker.

NOTE

On models with a secondary locking mechanism, loosen screw and rotate mechanism to an unlocked stated.

c. Position the rail lock lever to the up position and slide the coffee maker into the rail assembly and lock in place. If applicable, reposition secondary locking mechanism to locked position and tighten screw.

d. Close drain valve.

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

f. Depress ON/OFF switch to ON. Depress BREW switch to allow water to enter the brew chamber and the cof-fee server.

g. Depress ON/OFF switch to OFF and empty coffee server. The unit is ready for use.

3.2 PREPARATION FOR STORAGE OR SHIP-

MENT.

NOTE

On models with a secondary locking mechanism, loosen screw and rotate mechanism to an unlocked state.

a. Remove coffee maker from rail assembly by unlocking rail lock (rotating upward) and pulling outward on cof-fee maker.

b. Drain all liquid from coffee maker by opening drain valve.

c. Wipe all components with a clean, dry cloth.

d. Install protective covers over electrical and water con-nectors.

e. Put the coffee maker in its original shipping container for storage or pack unit for shipment in accordance with MIL-STD-2073-1.

Change 1 3-1/(3-2 blank)

CHAPTER 4

OPERATION INSTRUCTIONS

4.1 THEORY OF OPERATION.

Electrical power of 115/200 volts alternating current (VAC), 3-phase, 400 Hertz (Hz) and pressurized water of 28 ±4 pounds-force per square inch (PSI) are provided from the Air Transportable Galley Lavatory (ATGL) power sources to the connectors on the coffee maker rail assembly mounted in the galley. When the coffee maker is slid in and locked to the rail assembly, electrical and water connections are made.

Electrical power to the heating elements is controlled through a low-water probe in the coffee maker water tank. When the coffee maker water tank is full, the coffee maker probe com-pletes a circuit to the ON/OFF switch, which, when pushed, illuminates and completes a circuit to a relay. This relay in turn closes and completes the three-phase circuit to the water heating elements and makes a potential power source to the warming pad. When the brew switch is pushed, the light illuminates. When the water is at the desired temperature (190 ±3 °F), water will flow through the brew head and empty into the brew server. When the water level in the server reaches the sensing probes hanging in the coffee server, the brew switch is deactivated, and the brew cycle stops. If the hot water switch is pressed during the brew cycle, the cycle will stop and will begin again when the hot water switch is released and the water tank temperature reaches 190 ±3 °F. The warming pad is turned on with the warming pad switch. The power to the warming pad will remain on until the switch is deactivated or the power switch is turned off.

4.2 OPERATING INSTRUCTIONS.

(See Figure 4-1.)

Coffee maker warmer surfaces become extremely hot during operation. Use caution when working in and around these areas, as severe burns could occur. Use protective gloves or other suitable means of protection to avoid burns

a. Depress ON/OFF switch (1) on left-hand side of the control panel. The switch should illuminate, indicating power is applied to the coffee maker and water is be-ing heated.

b. Depress hot and cold water switches (10 and 11) until a steady flow of water is obtained to purge air from system.

c. Remove brew tray and coffee server by grasping the server (4) handle with right hand, press down and hold the retaining lever tab (2) down with right hand thumb and pull brew tray (3) and coffee server (4) outward.

d. Place the coffee bag into the brew tray (4) with the seam downward and running from front . to rear.

Slightly turn up the ends and sides of the coffee bag to ensure that it fits into the brew tray.

NOTE

It is essential that the sensing probes fall into the coffee server, as this cuts off the water supply when the server is full.

e. Install the empty coffee server (4) on the warming pad

(5) and ensure the sensing probes (6) are extending into opening of the coffee server.

f. Insert the brew tray (3) with the coffee grounds into the brew chamber and press the brew tray and coffee server retaining lever (2) down.

g. Depress the brew switch (8) and the warming pad switch (7). The coffee will brew when the water is at the correct temperature and will shut off automatically when the coffee is brewed. The warming pad will re-main on to keep the coffee hot until served. When the coffee server is removed or empty, tum off the warm-ing pad switch (7).

h. After each brew cycle, empty and rinse the coffee grounds from the brew tray.

i. If cold water is required, place container under spigot

(9) and depress and hold cold water switch (10) until desired amount of water is in the container.

j. If hot water is required, place container under spigot

(9) and depress and hold hot water switch (11) until desired amount of water is in container.

NOTE

When hot water is taken from the spigot during the brew cycle, brewing will stop and will not start again until the water is at the correct temperature.

k. When operation of the coffee maker is completed, the following procedural steps should be accomplished:

4-1

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

(2) Empty any leftover coffee and rinse coffee server (4).

(3) Turn off warming pad switch (7) and ON/OFF switch (1).

(4) Press retaining lever (2) down and install brew tray (3) and coffee server (4).

4.3 COLD WEATHER PROCEDURES.

(See Figure 4-2.)

If freezing temperatures are expected and the cof-fee maker is not to be used, the coffee maker wa-ter system must be drained to prevent damage by freezing.

a. Open WATER System (SYS) circuit breaker (TO 13B4-4-1, Figure 5-2, 7).

b. If freezing temperatures are expected, close potable water shut-off valve and drain coffee maker by depress-ing HOT WATER switch (Figure 4-1, 11) and COLD WATER switch (10). Drain remaining water by using drain valve (Figure 4-2, 1). Leave drain valve (1) open.

NOTE

On models with a secondary locking mechanism, loosen screw and rotate mechanism to an unlocked state.

c. If access to potable water shut-off valve is not pos-sible, unlock rail lock (2) and pull coffee maker (3) out of rail assembly (4). This will disconnect the water connection between the rail assembly and the coffee maker. Depress coffee maker water quick-disconnect (5).

NOTE

Do not connect coffee maker to rail assembly until ready for use. The coffee maker will fill automati-cally when connected to the water supply.

d. Drain water from the coffee maker by opening valve

(1) and allowing water to drain into drain cavity under rail assembly.

4.4 CONTROLS AND INDICATORS.

(See Figure 4-3.) Table 4-1 provides a description of the controls and indicators for the coffee maker.

Figure 4-1. Coffee Maker Operation

Figure 4-2. Coffee Maker Draining

4-2 Change 1

Table 4-1. Controls and Indicators

Control/Indicator Function ON/OFF SWITCH (1) Turns power on and off to coffee maker. Turning off will stop brewing process.

WARMING PAD SWITCH (2) Turns warming pad on and off. Will remain on until switch is turned off.

If ON/OFF switch (1) is turned off and warming pad switch (2) is on, the warming pad switch will remain on but inactive.

BREW SWITCH (3) Turns brewing process on. Process will remain on until coffee reaches the sensing probes or the ON/OFF switch (1) is turned off.

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

COLD WATER SWITCH (5) When depressed 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 sens-ing 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.

SECONDARY LOCKING MECHANISM

(13) Used to lock the rail lock.

Figure 4-3. Coffee Maker Controls and Indicators

Change 1 4-3/(4-4 blank)

CHAPTER 5

MAINTENANCE INSTRUCTIONS

5.1 GENERAL REQUIREMENTS.

To perform the operational checkout, cleaning procedures, and test procedures, a shop environment with the following is required:

a. Coffee maker rail assembly (PN 500-327-4) mounted on a work bench.

b. 115/200 volts alternating current (VAC), 3-phase, 400- Hertz (Hz) power source with ammeter, multimeter, thermometer, flowmeter and a 0-100 pounds-force per square inch (PSI) pressure gauge to simultaneously measure flow, pressures, and voltage.

c. 28 ±4 psi water source with an in-line shutoff valve, a flowmeter, and a supply tank that can be easily emp-tied and filled with water or vinegar.

d. Containers capable of holding vinegar and water for cleaning parts.

5.2 OPERATIONAL CHECKOUT.

(See Figure 5-1.)

a. Close potable water valve.

b. Install coffee maker into rail assembly.

c. Apply electrical power and open potable water valve.

NOTE

The heaters will not turn on during a low-water condition. The current draw on phases A and C will be zero while the current draw on phase B will be the current drawn by the control circuitry and the warmer pad.

d. Depress ON/OFF switch (1) to ON. Verify the condi-tion of the following Light-Emitting Diodes (LED).

(1) Red LED illuminates on the ON/OFF switch, in-dicating that power is applied to the brewer.

(2) Red LED illuminates on the WARMER switch (2), indicating the warming pad is operating.

(3) Red LED illuminates on the COLD WATER switch (5), indicating that the water level in tank is low. The water tank, initially empty, will fill up.

e. Depress hot and cold water switches (4 and 5) until a steady flow of water is obtained to purge air from sys-tem.

f. Depress WARMER switch (2) and ensure LED goes out and there is a reduction (approximately 0.5 am-peres (amp)) on phase B.

g. As the water level in the tank reaches the tank water level probes, the LOW WATER indicator LED will go out and the heaters will turn on. The current draw per phase will now be approximately 7.5 amps.

h. Insert the brew tray in the brew chamber and insert the coffee server on the warming pad. Ensure the sensing probes are inside the server.

i. Depress the BREW switch (3). The green LED in the BREW switch will flash.

NOTE

When the brew temperature is reached, the heaters will turn off and the brew cycle will begin. The BREW switch LED will now be a steady green.

j. Monitor the water flow on the flowmeter. The normal flow rate is approximately two gallons per minute.

k. Measure the initial temperature of the brewed water by placing the temperature measuring probe tip at the brew spout.

l. When the liquid level in the server reaches the coffee level probes, the brew cycle will stop. Measure the temperature of the water in the server per Paragraph

5.3. The server water temperature should be a mini-

mum of 145 °Fahrenheit (F). The heaters will remain on until the water temperature is a minimum of 145 °F.

m. Depress HOT WATER switch (4) during brew cycle.

Brew cycle should stop, green LED on BREW switch

(3) should flash, and hot water should flow from the spigot (12). After the switch is released the brew cycle will not start again until water reaches correct tem-perature.

n. Depress COLD WATER switch (5). Cold water should flow from spigot (12) and it should not affect the brew cycle.

5-1

o. Remove electrical power, wait 5 seconds, and apply electrical power. Verify that ON/OFF LED (1) illumi-nates.

Electrical power is applied. Ensure all precaution-ary measures are taken while top cover is removed.

Failure to adhere to warning may result in severe injury or death.

The printed circuit (PC) board has Electrostatic Discharge (ESD)-sensitive components. Observe electrostatic discharge precautions to prevent dam-age to printed circuit board.

p. Remove screws (Figure 5-2, 1) from top cover (2);

remove top cover.

q. Depress and hold HOT WATER switch (Figure 5-1, 4) until heaters go on and hot water LED goes out. Set position #1 on SW1 (3) to on. Verify the hot water LED illuminates and the heaters go off. Switch posi-tion #1 on SW1 (3) back to off position.

r. Remove electrical power.

s. Install top cover (Figure 5-2, 2) and screws (1).

5-2

Figure 5-1. Operational Checkout

5-3

Figure 5-2. Temperature Calibration

5-4

5.3 TEMPERATURE CALIBRATION.

(See Figure 5-2.) Following major overhaul or replacement of the thermistor and related temperature-detecting compo-nents, the brew temperature must be calibrated.

a. Close the potable water valve.

b. Install coffee maker into rail assembly.

c. Apply electrical power and open potable water valve.

Electrical power is applied. Ensure all precaution-ary measures are taken while top cover is removed.

Failure to adhere to warning may result in severe injury or death.

d. A fast and accurate calibration can be attained by low-ering the unknown temperature and gradually increas-ing it. To reduce the temperature, turn the screw on trimpot P1 (4) several turns counterclockwise. Run several brew cycles to stabilize the temperature.

e. After the temperature has stabilized, and with the heat-ers turned off, begin a new brew cycle. When the flow starts, place a thermometer directly into the flow of water below the coffee spout on the brew tray. If water temperature is below 190 ±3 °F, raise the water tem-perature by turning the trimpot screw P1 (4) clock-wise.

f. Repeat this process until correct temperature is reached.

g. Remove electrical power.

h. Install screws (1) and top cover (2).

5.4 INSPECTION AND PREVENTIVE MAINTE-

NANCE.

5.4.1 General. A preliminary cleaning (Paragraph 5.4.2)

before initial inspection will facilitate location of obvious defects. Visually inspect working parts for cracks using a magnifying glass under strong light. Inspect structure for distortion, corrosion, crossed or stripped threads, and exces-sive wear that might impair the function of equipment.

5.4.2 Cleaning. The coffee maker should be completely

cleaned periodically to coincide with the Air Transportable Galley Lavatory (ATGL) periodic inspection.

a. Drain coffee maker by removing from rail assembly and opening drain valve (Figure 5-1, 8).

b. Clean coffee maker external areas with a damp cloth.

c. Install coffee maker into rail assembly, empty the wa-ter supply tank.

d. Apply electrical power.

e. Fill water supply tank with white distilled vinegar.

f. Turn water supply tank potable water valve and the water pump switch to the on position to allow the cof-fee maker to fill with distilled vinegar.

g. Follow the steps outlined in operating instructions (Paragraph 4.2); allow vinegar to circulate through the system. After one pot of vinegar has been brewed, shut off electrical power and allow vinegar to stand in sys-tem for approximately 12 hours.

h. After the 12-hour period, drain vinegar from water supply tank and fill with water.

i. Apply electrical power. Following the operating in-structions outlined in Paragraph 4.2, circulate water through the coffee maker until all traces of vinegar are gone. Remove electrical power.

Do not immerse coffee maker in water. Damage to electrical components will result.

j. Wash coffee server and brew tray in warm water.

k. Using a damp cloth, clean the coffee server cavity, the warming pad, the brew tray cavity, and the sensing probe of any coffee residue or dirt.

l. Perform the operational checkout of the coffee maker per Paragraph 5.2.

5.4.3 Electrical Inspection.

a. Remove coffee maker from rail assembly.

b. Inspect electrical wiring and connection points for damage, deteriorated insulation, and loose or burnt wires.

c. Check coffee maker electrical connector for loose, bent, or broken pins; deformed shells; and evidence of arcing or flashover at pin insert insulation.

d. Check terminal strip for cracked insulation and loose terminals.

5-5

e. Check terminal strip cover for cracks.

f. Ensure the coffee server sensing probes are free of dirt or oils.

5.4.4 Plumbing.

a. Check tubing for leakage and flattening; check for crimped, split, loose, or worn fittings.

b. Check tank assembly for leaks, deterioration, or cracks.

c. Check for leaks and check sealing around the edges of the warming pad. If seal is leaking or is unserviceable, remove old sealant, clean area thoroughly, and apply a new coat of RTV732 black silicone rubber to the edges.

5.5 TROUBLESHOOTING.

Allow coffee maker to cool down prior to per-forming maintenance. Hot water tank surfaces are extremely hot after operation and could cause se-vere bums.

Table 5-1, Troubleshooting, lists symptoms, their probable cause, and the corrective action.

a. Troubleshooting procedures can be performed in either the ATGL or in the shop.

b. Ensure that the water potable tank is serviced with wa-ter. With normal voltage applied, actuate all necessary switches, circuit breakers, and the water source.

Table 5-1. Troubleshooting

Symptom Probable Cause Corrective Action Coffee maker fails to operate when ON/OFF switch is depressed

Thermistor Replace thermistor (Paragraph 5.6.10).

Low-water probe Clean or replace (Paragraph 5.6.11).

ON/OFF switch Replace switch panel assembly (Paragraph 5.6.2).

Relay Replace relay (Paragraph 5.6.21).

Printed circuit (PC) board Replace PC board Paragraph 5.6.3).

No water flow to coffee maker

Low water supply Fill tank.

Coffee maker improperly installed on rail assembly Check coffee maker for proper installation.

Solenoid valve Repair or replace Paragraph 5.6.8).

Line plugged Isolate and clear.

Heating element Replace (Paragraph 5.6.13).

Warming pad heating element Replace (Paragraph 5.6.4).

Coffee server overflows Sensing probes improperly placed Insert sensing probes in coffee server.

Probe dirty Clean and check probe contacts.

Coffee not hot enough PC board Adjust or replace (Paragraph 5.3 or Paragraph 5.6.3).

Heating element Replace (Paragraph 5.6.13) Warming pad heating element Replace (Paragraph 5.6.4).

Water leaks through brew head when coffee maker is turned off

Brew solenoid valve Clean, repair, or replace (Paragraph 5.6.8).

Hot water leaks from spigot

Center solenoid valve Clean, repair, or replace (Paragraph 5.6.8).

5-6

Table 5-1. Troubleshooting - Continued

Symptom Probable Cause Corrective Action Cold water leaks from spigot Bottom solenoid valve Clean, repair, or replace (Paragraph 5.6.8).

Water leaks continuously from bottom of coffee maker

Bottom solenoid valve Clean, repair, or replace (Paragraph 5.6.8).

Auto-vent valve Replace (Paragraph 5.6.7).

5.6 REPAIR.

5.6.1 General. The following paragraphs describe com-

ponent removal and installation procedures. When appli-cable, paragraphs will cover the repair, cleaning, inspection, and testing of the components.

5.6.2 Switch Panel Assembly Replacement. (See Fig-

ure 5-3.)

a. Removal.

(1) Remove screws (2) that secure top cover (3); re-move cover.

The PC board has ESD-sensitive components. Ob-serve electrostatic discharge precautions to prevent damage to printed circuit board.

(2) Disconnect printed circuit board ribbon cable

(1) from switch panel assembly (4).

(3) Remove two screws (5) and washers (6) that se-cure switch panel assembly (4) in place.

Figure 5-3. Coffee Maker Push Button Switch Replacement

5-7

(4) Remove switch panel assembly (4) by pulling forward gently.

b. Installation.

(1) Position switch panel assembly (4) into place and insert two screws (5) and washers (6).

The PC board has ESD-sensitive components. Ob-serve electrostatic discharge precautions to prevent damage to printed circuit board.

(2) Connect printed circuit board ribbon cable (1) and perform an operational check.

(3) Position top cover (3) and install screws (2).

5.6.3 Printed Circuit Board Replacement. (See Fig-

ure 5-4.)

The PC board has ESD-sensitive components. Ob-serve electrostatic discharge precautions to prevent damage to the printed circuit board.

a. Removal.

(1) Remove screws (2) that secure top cover (3); re-move cover.

(2) Disconnect printed circuit board ribbon cable (1) from switch panel assembly (4).

(3) Remove two screws (5) that secure printed circuit board (6).

(4) Grasp printed circuit board by the forward edge and slide forward to disconnect PC board from connector (7). Retain spacers (8) for installation.

b. Installation.

(1) Install printed circuit board (6) in coffee maker;

align connector (7) and engage connector.

(2) Install two screws (5) to secure printed circuit board. Ensure spacers (8) are installed between printed circuit board (6) and top of coffee maker.

(3) Connect printed circuit board ribbon cable (1) to switch panel (4).

(4) Install top cover (3) and install screws (2).

Figure 5-4. Coffee Maker PC Board Removal

5-8

5.6.4 Warming Pad Heating Element Replacement.

(See Figure 5-5.)

a. Removal.

(1) Remove screw (1), locknut (2), and washer (3);

remove warmer pad heater (4).

(2) Trace wires from warming pad heater to terminal board (5).

(3) Remove tie wrap from wire bundles and separate wires.

(4) Remove terminal board cover and disconnect warmer pad heater wires from terminal posts 1 and 4.

b. Installation.

(1) Install warmer pad heater (4) on coffee maker, install screw (1), washer (3), and locknut (2).

(2) Route wires to terminal board (5) and install one wire on terminal post 1 and one on terminal post 4 and perform operational clock.

(3) Install terminal board cover.

(4) Secure warming pad heater wires to bundle with tie wrap.

5.6.5 Tubing Replacement. (See Figure 5-6.) The coffee

maker contains two types of tube fittings, barb and compres-sion.

a. Removal of barb fittings.

(1) Cut the tube the length of the hose end fitting.

(2) Remove tubing from hose fitting.

b. Removal of compression fittings.

(1) Remove connector (3) from nipple.

(2) Remove tube from component.

c. Installation of barb fittings.

Figure 5-5. Coffee Warming Pad Removal

5-9

NOTE

If tubes are removed for reasons other than being clogged or deteriorated the tube may be reused. If tube is to be reused omit steps 1 through 3.

(1) Fabricate a piece of tubing of the correct size and length.

(2) Cut end of tubing squarely.

(3) Ream out the inside of the tube end.

(4) Remove all chips from tube and flush with water.

(5) Lubricate end of tube with soapy water and slide onto fitting.

(6) Perform operational and leak check.

d. Installation of compression fittings

(1) Obtain a piece of tubing the correct length.

(2) Cut end of tubing squarely.

(3) Slide fitting parts (1) onto tube (2) and fit to-gether.

(4) Tighten connector (3) onto nipple; fitting will compress during tightening.

(5) Perform operational and leak check.

5.6.6 Pressure Relief Valve Replacement. (See Figure

5-6.)

a. Removal.

(1) Remove tube (4) from cap assembly (5) per Para-graph 5.6.5, Step a.

(2) Remove cap assembly (5) from pressure relief valve (6).

(3) Remove pressure relief valve from water tank (7).

b. Cleaning. The following procedures are required only when water is leaking from the valve and a new valve is not available.

(1) Disassemble valve and wash parts with water. If water does not remove all particles, soak parts in vinegar for approximately 12 hours.

(2) Reassemble valve.

(3) Apply pressure to valve. Valve should open at 65 ±5 PSI. If valve does not open or opens sooner when this pressure is applied, replace valve.

c. Installation.

(1) Apply antiseize tape to threads of pressure relief valve (6).

(2) Install pressure relief valve into water tank (7) with arrow pointing away from tank.

(3) Install cap assembly (5) onto pressure relief valve (6).

(4) Install tube (4) onto cap assembly (5) per Para-graph 5.6.5, Step c.

(5) Perform operational and leak check.

5.6.7 Vent Valve Replacement. (See Figure 5-6.)

a. Removal.

(1) Remove tube (8) from outlet body assembly (9) per Paragraph 5.6.5, Step a.

(2) Remove outlet body assembly (9) from vent valve assembly (10).

(3) Remove vent valve assembly from water tank (7).

b. Installation.

(1) Apply antiseize tape to threads on both sides of vent valve assembly (10).

(2) Install vent valve assembly into water tank (7).

(3) Install outlet body assembly (9) onto vent valve assembly (10).

(4) Install tube (8) onto outlet body assembly (9) per Paragraph 5.6.5, Step c.

(5) Perform operational and leak check.

5-10

Figure 5-6. Coffee Maker Plumbing Installation

5-11

5.6.8 Solenoid Valve Replacement. (See Figure 5-6.)

Three solenoid valves (11, 12, and 13) are connected to-gether with tees (14) to make an assembly. To repair or re-place any one of the three valves (brew, hot, or cold), re-move the entire assembly.

a. Removal.

(1) Tag and remove wires from terminals on sole-noids (11, 12, and 13). (See FO-1 for wire rout-ing.)

(2) Remove tubes (15, 16, and 17) per Paragraph 5.6.5, Step b.

(3) Remove tube (Figure 5-7, 12) from solenoid as-sembly.

(4) Remove two screws (Figure 5-6, 21) that secure solenoid bracket (22) to back wall.

(5) Pull the solenoid valves assembly off and out.

b. Disassembly.

(1) The three valves should be separated if a valve in the group needs to be replaced. To separate, un-screw valve from tee (14).

(2) Remove remaining tee.

c. Repair. (See Figure 5-7.) Repair consists of cleaning or replacement of plunger, spring, and 0- ring.

(1) Remove screws (Figure 5-6, 23) that secure sole-noid bracket (22) to solenoids.

(2) Remove nut (Figure 5-7, 1) from plunger housing (2); remove coil (3).

The plunger housing is hollow; do not squeeze.

Failure to observe this caution may result in equip-ment damage.

(3) Position tool (4) on plunger housing (2) as shown;

using wrench, turn counterclockwise to remove.

(4) Remove plunger (5) and spring (6) from plunger housing (2).

(5) Remove packing (7) from body (8).

(6) Clean plunger housing (2) and body (8) by soak-ing in vinegar for approximately 12 hours and rinsing with water.

d. Assembly.

(1) If valves are separated, assemble by installing tee (14).

(2) Install spring (6) and plunger (5) into plunger housing (2).

(3) Install packing (7) into body (8).

(4) Install plunger housing (2) into body (8). Use tool

(4) and a wrench to tighten.

(5) Install coil (3) onto plunger housing (2) and in-stall nut (1).

(6) Assemble valve group by installing valve in tee (14).

e. Installation. (See Figure 5-6.)

(1) Position the solenoid valves assembly so it will go through hole in bulkhead and meet spigot (19).

(2) Install two screws (21) that secure solenoid bracket to the coffee maker.

(3) Install tube (Figure 5-7, 12) to solenoid valve as-sembly and tighten.

(4) Install tubes (Figure 5-6, 15, 16 and 17) per Step d.

(5) Remove tags and install wires to terminals on flow-control valves (11, 12, and 13). (See FO-1 for wire routing.)

(6) Perform operational and leak check.

5-12

5.6.9 Flow Restrictor Replacement. (See Figure 5-7.)

a. Removal.

(1) Remove hose connector (9) from elbow (10).

(2) Remove flow restrictor (11) from connector (9).

b. Cleaning.

(1) Inspect flow restrictor for obstructions or foreign objects.

(2) Clean as required.

c. Installation.

(1) Install flow restrictor (11) in hose connector (9).

(2) Apply antiseize tape to threads of hose connector

(9) and install into elbow (10).

(3) Perform operational and leak check.

5.6.10 Thermistor Replacement. (See Figure 5-8.)

a. Removal.

(1) Remove terminal board cover (Figure 5-10, 6), and remove thermistor wires from terminal posts 5 and 6. Refer to FO-1.

(2) Cut tie wraps from wire bundle and separate wires.

Figure 5-7. Flow Control Valve Repair

Figure 5-8. Coffee Maker Repair

5-13

(3) Remove thermistor (Figure 5-8, 1) from water tank (3).

b. Installation.

(1) Apply antiseize tape to thermistor threads and in-stall thermistor (1) into water tank (3).

(2) Install wires on terminal board (2) and install one wire on terminal post 5 and one wire on terminal post 6. Install terminal board cover (Figure 5-10, 6).

(3) Secure thermistor wires to wire bundle with tie wraps.

(4) Perform operational and leak check.

5.6.11 Low-Water Probe Replacement. (See Figure

5-8.)

a. Removal.

(1) Remove wire from PC board connector to low-water probe (4); refer to FO-1.

(2) Remove low-water probe (4) from water tank (3).

b. Cleaning.

(1) Soak probe in vinegar for…