25-32-24 Rev.03 CoffeeMaker 72012400 PDF

COMPONENT
MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
ROYAL
COMPANY
COFFEE MAKER
DA 24 SERIES
PART NUMBERS
72012400, 72012410, 72012420
Revision 3
July 1, 1997
25-31-24 Title Page 1

July 1, 1997
DA 24 Series COMPONENT
MAINTENANCE MANUAL
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July 1, 1997
MAINTENANCE MANUAL
RECORD OF REVISIONS
Rev.No Issue Date Date Inserted By
1 July 01, 1993

2 April 1, 1996
3 July 1, 1997
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MAINTENANCE MANUAL
RECORD OF TEMPORARY REVISIONS
Temp Issue Inserted Date Removed Date

Rev.No. Date By By
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March 01/93
MAINTENANCE MANUAL
SERVICE BULLETIN LIST
S.B. NUMBER ISSUE DATE SUBJECT INCORPORATED

DATE / BY
DA24-25-1 February 1, 1992 Introduction of part numbers
Superseded by Rev A
DA24-25-1/ A August 1, 1992 Introduction of part numbers
Superseded by Rev B
DA24-25-1 / B October 1, 1992 Introduction of part numbers
DA24-25-2 February 1, 1992 Thicker studs on brew compartment
DA24-25-3 September 15, 1992 Part number for level sensor assembly
DA24-25-4 January 1, 1993 New locking assembly
DA24-25-5 January 1, 1993 New springs for locking assembly
DA24-25-6 February 1, 1993 New connector
DA24-25-7 February 1, 1993 Introduction of new parts
DA24-25-8 November 15, 1993 Introduction of new switch panel PCB
DA24-25-9 January 1, 1994 Introduction of new control PCB
DA24-25-10 December 1, 1993 Introduction of new vent valve
DA24-25-11 January 1, 1994 New switch panel for
Ser. No.s 0001-0199
DA24-25-12 January 1, 1994 Alternate top panel
DA24-25-13 January 1, 1994 New solenoid valves
DA24-25-14 April 1, 1996 New LED
DA24-25-15 January 1, 1996 Introduction of new lock assy
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April 1, 1996 Revision 2
MAINTENANCE MANUAL
LIST OF EFFECTIVE PAGES
This manual has the following pages:
Page Date
Title Page July 1, 1997

Record of Revisions July 1, 1997
Record of Temporary Revisions March 01-1993
Service Bulletin List April 1, 1996
List of Effective Pages July 1, 1997
Table of Contents April 1, 1996
Introduction Page 1 July 01-1993
Page 2 March 01-1993
Page Date Page Date Page Date
1 April 1, 1996 111 April 1, 1996 501 April 1, 1996

502 April 1, 1996
2 April 1, 1996 112 April 1, 1996
602 April 1, 1996
4 April 1, 1996 114 April 1, 1996
7 April 1, 1996 703 April 1, 1996
304 April 1, 1996 707 April 1, 1996
101 July 1, 1997 305 April 1, 1996 708 April 1, 1996
102 July 1, 1997 306 April 1, 1996 709 April 1, 1996
103 July 1, 1997 307 April 1, 1996 710 April 1, 1996
104 July 1, 1997 308 April 1, 1996
105 July 1, 1997 309 April 1, 1996 801 April 1, 1996
310 April 1, 1996 802 April 1, 1996
106 July 1, 1997
107 July 1, 1997 901 April 1, 1996
108 July 1, 1997 902 April 1, 1996
109 July 1, 1997 401 April 1, 1996
110 July 1, 1997 402 April 1, 1996
403 April 1, 1996
404 April 1, 1996
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Page Date Page Date Page Date

1030 April 1, 1996 1060 April 1, 1996
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July 1, 1997
MAINTENANCE MANUAL
TABLE OF CONTENTS
Subject Page
Description and Operation 1

Testing and Fault Isolation 101
Disassembly 301
Cleaning 401
Check 501
Repair 601
Assembly 701
Fits and Clearances 801
Special Tools, Equipment and Materials 901
Illustrated Parts list 1001
ILLUSTRATIONS
Title Figure No
DA 24 Coffee Makers - General 1

Wiring Diagram - Coffee Maker 2
Wiring Diagram - Coffee Maker 3
PCB Test 101
Removal / Installation Tool 7S608998 901
Lens Tool 7S610015 902
LED Tool 7S610016 903
DA 24 Series Coffee Maker IPL 1
Mechanical Installation IPL 2
Pillow Pack Holder & Coffee Server IPL 3
Locking Assembly IPL 4A & B
Water System (Sheet 1 of 2) IPL 5A
Water System (Sheet 2 of 2) IPL 5A
Water System (Sheet 1 of 2) IPL 5B
Water System (Sheet 2 of 2) IPL 5B
Electrical System (Sheet 1 of 2) IPL 6
Electrical System (Sheet 2 of 2) IPL 6
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Title Figure No.
Printed Circuit Board Assy IPL 7A

Printed Circuit Board Assy IPL 7B
Control Panel Assembly - 7S610005 IPL 8
Printed Circuit Board - Control Panel IPL 9
Mounting Rail Assembly (Optional) IPL 10
Switch Module Assembly - 7S610994 IPL 11
Solenoid Valve - 7S239107 IPL 12
Level Sensor and Vent Valve Assemblies IPL 13
Switch Module Assembly - 7S611047 IPL 14
Modification Kit New Lock Assembly 7S611444 IPL 15
"END"
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MAINTENANCE MANUAL
INTRODUCTION
1. General
This manual is prepared in accordance with:
-Specification ATA 100, Revision 26, dated April 01 1987, where applicable
and as much as practicable.
-Association Europeenne des Constructeurs de Materiel Aerospatial
(AECMA) Simplified English.
-International Electrotechnical Commission (I.E.C.), Publication 617 Series,
Graphical Symbols for Diagrams.
This manual contains instructions for the overhaul and testing of the Coffee
Makers as manufactured by Royal Inventum Company (INVENTUM):
MODEL PART No. SERIAL No. Eff:
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 0001 and up D
Dissassembly, Assembly, Test and Fault Isolation procedures have been verified by
the engineering department of INVENTUM.
2. Numbering System
25 - 31 - 24
The first element (25) of this number is the chapter number established by Air
Transport Association of America (ATA) Specification 100 and identifies the
SYSTEM / CHAPTER (Equipment and Furnishings) of which this unit is a part.
The first digit of the second element (31) of this number, also specified by ATA
Specification 100 identifies the SECTION / SUB-SYSTEM (Buffet/Galley) of which
this unit is a part.
The second digit of the second element (31) of this number is assigned by
INVENTUM and identifies the SECTION / SUB-SUBSYSTEM (Coffee Makers) to
which this manual refers.
The third element (24) of this number is assigned by the INVENTUM and identifies
the SUBJECT / UNIT to which this manual refers.
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MAINTENANCE MANUAL
3. General Maintenance Practices
NOTE : These procedures are intended for use during routine maintenance and for
use in the overhaul shop.
A. Cleaning
(1) Daily:
- Remove the coffee server

- Use absorbent cloths and household detergent to clean the inside and
outside of the coffee maker and the server
- Use absorbent cloths and clean water to rinse the inside and outside of the
coffee maker and the server
- Use absorbent cloths to dry the coffee maker and the server
- Install the server.
B. Decalcification
(1) Depending on the quality of the water that is used for making coffee, the boiler assembly
of the coffee maker must be decalcified
(Refer to Pageblock 401).
It is recommended that this be done every 1500 to 2000 flight hours.
C. Inspection
(1) Weekly, make sure that:
-there is no evidence of internal leakage

- there is no evidence of external leakage
- the coffee maker operates correctly
- the digital indicator operates correctly
Faults must be corrected.
"END"
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MAINTENANCE MANUAL
DESCRIPTION AND OPERATION
1. General
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 0001 and up D
The coffee makers, type DA 24, are designed to supply freshly brewed coffee and hot
and cold water.
The coffee makers have: -a coffee pillow pack

-a coffee server
-a server locking assembly
-a coffee level sensor assembly
-a boiler assembly
-heating elements
-a warmer pad
-a hot / cold water tap
-a temperature sensor (thermistor)
-a water level sensor
-3-phase safety-device
-a pressure relief valve
-a vent valve
-a drain
Effectivity: A Effectivity: B,C,D

-a control panel - a switch module assembly
-a solenoid valve - three solenoid valves.
The dimensions of the coffee maker, not including the electrical and water connectors
are:
-Height 304 mm (11.97 in)

-Width 160 mm (6.30 in)
-Depth 346 mm (13.62 in).
The total empty weight of the coffee maker is 8,0 kg (17,6 lb).
The total full weight of the coffee maker is 11,0 kg (24,3 lb).
The water inlet pressure must be 25 - 40 psi.
Mounting racks, P/N 7S609609, 7S609642 or 7S609669 are available.
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DA 24 Coffee Makers - General

Figure 1
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2. Description
The power rating of each of the three heating elements in the boiler assy is 833 watts,
which gives a total power rating of 2500 watts.
The power rating of the warmer-pad heating-element under the coffee server position
is 50 watts. The power supply to the coffee maker is 115/200 Vac, 3 phase, 400 Hz.
The control circuit uses 28 Vdc, 30 watts.
The coffee maker makes 1,5 liters of coffee in one brew cycle. The time to heat the
water to 92 °C ± 3 °C (198 °F ± 5 °F) is about three minutes. The time to brew the
coffee, after the water is hot, is 2 - 3 minutes. The restrictor controls the flow of
water to the pillow pack.
In service, the coffee maker is mounted on a mounting rail that is installed in the
galley cavity. The mounting rail allows quick removal/installation. The electrical and
water connections are made automatically as the coffee maker is pushed rearwards.
The water connection is self sealing. The coffee maker is locked to the mounting rail
with a primary lock and a secondary lock that engage as the coffee maker is pushed
rearwards.
3. Operation [Effectivity: A (Pre SB DA24-25-11)]
The coffee maker operates when:
- The lock lever is in the locked (down) position. The lock lever holds the
coffee server in position.
- The boiler assembly of the coffee maker has enough water. The water level
sensor in the top of the boiler assembly senses when there is enough water in
the boiler.
The CODE indicator shows 01 when the coffee maker is unserviceable.
The coffee maker fills with water when the potable water supply is connected and
turned on. The vent valve, located on the top of the boiler assembly bleeds air as the
water level increases. The valve stays in the open position until the level of the water
pushes a ball upwards in its housing. This ball closes the orifice in the top of the boiler.
A. When power is supplied to the coffee maker, the boiler assembly is full of water
and the ON/OFF switch is set to ON:
-The ON/OFF light comes on.
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-The CODE indicator shows 00 when the coffee maker is ready for use.
-The heating elements in the boiler assy heat the water to a temperature of
92 °C ± 3 °C (198 °F ± 5 °F) in approximately three minutes.
-The temperature sensor measures the temperature of the water and when it
reaches 92 °C ± 3 °C (198 °F ± 5 °F), the WATER HOT light comes on.
B. When the WATER HOT light is on, the BREW switch is pushed in and the lock
lever is in the locked position:
-The BREW light comes on.

-The brew valve opens, hot water flows through the coffee in the pillow pack and
into the coffee server.
-The heating element of the warmer pad comes on.
NOTE: to turn off the heating element of the warmer pad, push the
HOT PLATE push switch.
-Cold water comes into the boiler assy and replaces the used hot water
-When the temperature at the front of the warmer pad is greater than
50 °C (122 °F), the PLATE HOT light comes on.
C. When the level of the liquid in the coffee server reaches the level sensor:
-The brew valve closes and the flow of water to the pillow pack stops.
-After 15 seconds the BREW READY light comes on and the BREW light
goes off.
D. The coffee is ready to be served.
NOTE: If it becomes necessary to interrupt the brew cycle, i.e. to replace a

pillow pack, push (in) the ON/OFF switch or lift the lock lever. The
pillow pack holder cannot be removed until the lock lever has been lifted.
The brew cycle can be continued when the WATER HOT light is on and
the BREW switch is pushed (in) again.
E. Hot and Cold Water Supply
The coffee maker supplies cold water when the knob of the rotary faucet in the
center of the control panel is set to COLD. Hot water is supplied when the knob of
The rotary faucet is set to HOT.
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F. Temperature Control
The temperature sensor, also in the top of the boiler assy, measures the
temperature of the water and turns the power to the heating elements off, when the
water temperature reaches 92 °C ± 3 °C (198 °F ± 5 °F).
If the temperature sensor does not operate, the three-phase safety device turns the
power off when the water reaches a temperature of 110 °C ± 8 °C
(230 °F ± 12 °F).
G. Pressure Control
A pressure relief valve operates when the pressure in the boiler assy reaches
77 - 85 psi.
4. Operation (Effectivity B,C,D)

(A Post SB DA24-25-11)
The coffee maker operates when:
-The the lock lever is in the locked (down) position. The lock lever holds the
coffee server in position.
-The boiler assembly of the coffee maker has enough water. The water level
sensor in the top of the boiler assembly senses when there is enough water in
the boiler.
The NO WATER ? / OUT OF ORDER light comes on when there is not enough
water in the boiler or when the coffee maker is unserviceable.
The coffee maker fills with water when the potable water supply is connected and
turned on. The vent valve, located on the top of the boiler assembly, bleeds air from
the boiler as the water level increases. The valve stays in the open position until the
level of the water pushes a ball upwards in its housing. This ball closes the orifice in
the top of the boiler.
A. When the electrical power is supplied to the coffee maker, the boiler is full of
water and the ON/OFF switch is set to ON:
-The heating elements in the boiler heat the water to a temperature of

92 °C ± 3 °C (198 °F ± 5 °F) in approximately three minutes.
-The heating element of the warmer pad comes on. This keeps the coffee in the
coffee server warm.
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-The temperature sensor measures the temperature of the water and when
the temperature reaches 92 °C ± 3 °C (198 °F ± 5 °F), the WATER IS HOT
light comes on.
B. When the WATER IS HOT light is on, the BREW switch is pushed in and the
lock lever is in the locked position:
-The brew valve opens, hot water flows through the coffee in the pillow pack and
into the coffee server and the BREW light comes on.
-Cold water comes into the boiler to replace the hot water that has been used.
C. When the level of the liquid in the coffee server reaches the level sensor:
-The brew valve closes and the flow of water to the pillow pack stops.
-In 10 to 20 seconds the BREW READY light comes on and the BREW light goes
off.
D. The coffee is ready to be served.
NOTE: If it becomes necessary to interrupt the brew cycle, i.e. to replace a

pillow pack, push (in) the ON/OFF switch or lift the lock lever. The
pillow pack holder cannot be removed until the lock lever has been lifted.
The brew cycle can be continued when the WATER IS HOT light is on
and the BREW switch is pushed (in) again .
E. Hot and Cold Water Supply
(For effectifity A, refer to paragraph 3.E.)

The coffee maker will supply cold water when the COLD WATER switch is
pushed in. Hot water is supplied when the the HOT WATER switch is pushed in.
F. Temperature Control
The temperature sensor, in the top of the boiler, measures the temperature of the
water and turns the power to the heating elements off, when the water temperature
reaches 92 °C ± 3 °C (198 °F ± 5 °F).
Should the temperature reach 100 °C ± 3 °C (212 °F ± 5 °F), the PCB turns the
power to the heating elements off.
If the temperature sensor or the PCB fail to turn off the power, the three-phase
safety-device turns the power off when the water reaches a temperature of
110 °C ± 7.5 °C (230 °F ± 12 °F).
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G. Pressure Control
A pressure relief valve operates when the pressure in the boiler reaches 80 - 85 psi.
5. Equipment designators
EQUIPMENT DESIGNATOR NOMENCLATURE IPL FIGURE/

ITEM NO.
B1 3-Phase Safety-device 6 - 370

C 21 thru C24 Capacitor 6 - 310
D1, 2 Diode 6 - 430
H1 thru H3 Heating Element (Boiler) 5B - 450
H4 Heating Element (Server) 6 - 240
J1 Connector to the PCB 6 - 410
J2 Connector to the 6 - 380
Control panel / Switch module
J3 Terminal Strip 6 - 340
J4 Connector to Aircraft Electrical 6 - 460
System
K1 Relay 6 - 330
K2 Eff: B,C Relay 6 - 530
LS1 Level Sensor (Boiler) 5B - 350
LS2 Level Sensor (Server) 4
S3 Opto-coupler 6 - 170
S4 Eff: A Switch 6 - 230
T1 Temperature Sensor 5B - 340
V1,2, 3 Solenoid Valve 5B - 290B
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Wiring Diagram - Coffee Maker

Figure 2
Effectivity: A
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Wiring Diagram - Coffee Maker

Figure 3
Effectivity: B, C, D
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TESTING AND FAULT ISOLATION
1. General
If any work has been done to the coffee maker, the following tests must be done to
prove the serviceability of the unit. If necessary, refer to the Illustrated Parts List
(IPL).
2. Test Equipment
CAUTION: THIS TEST PROCEDURE IS WRITTEN FOR THE GENERAL

GUIDANCE OF COMPETENT AND EXPERIENCED ELECTRICAL
SERVICE PERSONNEL.
TURN THE ELECTRICAL POWER OFF WHEN MAKING OR
REMOVING ELECTRICAL TEST CONNECTIONS.
Use tools, fixtures and equipment normally available at overhaul facilities.
3. Effectivity
MODEL PART No. SERIAL No Eff:
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 0001 and up D
4. Procedure
A. Prepare to do the test
(1) Install the coffee maker, mounted in the rail, on the test-bench.
(2) Install thermocouples to make sure the cut-out temperature of the 3-phase
safety-device and the temperature of the water at the nozzle are correct.
(3) Use a graduated Measuring Jug instead of the server to measure the volume of water.
(4) Connect the electrical power to the coffee maker.
(5) Connect the water supply, with a pressure of 1,4 bar (20 psi), to the coffee
maker, but do not fill the boiler.
(6) Put the server lock in the down (locked) position.
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B. Do the test (Effectivity: A)
WARNING: BE CAREFUL WHEN YOU DO THE TEST. CONTACT WITH

HOT WATER CAN BE DANGEROUS.
NOTE: The coffee maker is empty at the start of the test.
ACTION RESULT
Set the ON/OFF switch to ON The ON/OFF light comes on
The Code shows 01
The WATER HOT red LED comes on.
Push the BREW switch There must be no results
Turn on the water supply and adjust it to the aircraft system When the boiler assembly is full
pressure -The CODE shows 00.
-The WATER HOT light goes off
-Power to the heating elements comes on.
After 2- 3 minutes, the WATER HOT red LED light
comes on and the water in the boiler is at brew temperature
Measure the current at each phase Requirements
L1 = 7.70 ± 0.7 Amps.(incl. Hot Plate Element).
L2 = 7.25 ± 0.5 Amps.
L3 = 7.25 ± 0.5 Amps.
Note: If the vent valve does not operate correctly, water will flow from the water hose and the drain.
Note: During brew cycle, the water pressure must be 1.37 bar (20psi).
Push the BREW switch and measure the temperature of the The BREW light comes on.
water at the nozzle The HOT PLATE light comes on.
The water flows in the Graduated Measuring Jug.
The water temperature must be
86 ± 3°C (186.8 ± 5.4°F)
NOTE: The WATER HOT light may go off because cold water that enters the boiler cools the contents.
After one minute, lift the handle of the server lock. The waterflow stops.
The BREW green LED goes off.
There must be 0.650 ± 0.05 ltr. (0.172 ± 0.013 USgal) in
the receptacle.
Remove the graduated measuring jug and install the server.
Put the server lock in the down (locked) position.
Push the BREW switch When water is hot, the WATER HOT red LED comes on,
the water flows from the nozzle.
Measure the water temperature at the nozzle. The temperature must be 89 ± 3 °C (192.2 ± 5.4°F)
When the server is filled with water: The water flow stops.
There must be 1,5 ± 0.2 ltr (0.396 ± 0.053 USgal) in the
server.
After 15 ± 5 seconds, the BREW READY LED comes on
and the BREW LED goes off.
Hold a container under the water tap and set the 3-way tap Cold water flows from the water tap.
to COLD.
Set the 3-way tap to HOT. Hot water flows from the water tap.
Set the 3-way tap to HOT until all the hot water is removed from the coffee maker.
Set the ON/OFF switch to OFF and remove the electrical power from the coffee maker.
Note: The 3-phase safety-device is a "sleeping" protection device and must be tested for correct operation after
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ACTION RESULT
maintenance.
Disconnect the Thermistor and replace it by a Test Thermistor
Connect the electrical power to the coffee maker and set After approximately 2 minutes, the 3-phase safety-device
the ON/OFF switch to ON, cuts off the power to the coffee maker.
Drain the coffee maker with open water system by using the 3-way tap in hot position and allow the coffee maker to cool
off.
Reset the 3-phase safety device and reconnect the original Thermistor.
CAUTION: OBSERVE THE STANDARD PRECAUTIONS WHEN YOU DO THE PRESSURE TEST.
Pressure Relief Valve Test
Switch the main Power to on and refill the Coffee Maker. The pressure relief valve opens at:
Close the water system after the Coffee Maker is refilled. 5.6 ± 0.3 bar (82 ± 5 psi).
Allow the Coffee Maker to warm up from cold.
Check the water section and make sure that there are no
leakage.
END OF TEST PROCEDURES
C. Do the test (Effectivity: B,C,D)
WARNING: BE CAREFUL WHEN YOU DO THE TEST. CONTACT WITH

HOT WATER CAN BE DANGEROUS.
NOTE: The coffee maker is empty at the start of the test.
ACTION RESULT
Set the ON/OFF switch to ON The ON/OFF light comes on
The OUT OF ORDER light comes on
The WATER IS HOT light comes on.
Push the BREW switch. There must be no results
Turn on the water supply and adjust it to the aircraft system When the boiler assembly is full:
pressure -The WATER IS HOT light goes off.
-The OUT OF ORDER light goes off.
-Power to the heating elements comes on.
After 2-3 minutes,, the WATER IS HOT light comes on
and the water in the boiler is at brew temperature.
Measure the current at each phase Requirements
L1 = 7.70 ± 0.7 Amps.(incl. Hot Plate Element).
L2 = 7.25 ± 0.5 Amps.
L3 = 7.25 ± 0.5 Amps.
Note: If the vent valve does not operate correctly, water flows from the water hose and the drain.
Note: During brew cycle, the water pressure must be 1.37 bar (20psi).
Push the BREW switch and measure the temperature of the The BREW light comes on.
water at the nozzle. The water flows in the Graduated Measuring Jug
The water temperature must be 86°C ± 3°C (first tap).
NOTE: The WATER IS HOT light may goes off, because cold water that enters the boiler cools the contents.
After one minute, lift the handle of the server lock The waterflow stops
The BREW light goes off.
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ACTION RESULT
There must be 0.650 ± 0.05 ltr. in the Graduated
Measuring Jug.
Remove the Graduated Measuring Jug and install the server.
Put the server lock in the down (locked) position.
Push the BREW switch When the water is hot the WATER IS HOT light comes
on, the water flows from the nozzle.
Measure the water temperature at the nozzle. The temperature must be 89 ± 3°C (second tap).
When the server is filled with water: The water flow stops
There must be 1.5 ± 0.2 ltr. in the server.
After 15 ± 5 seconds, the BREW READY light comes on.
Hold a container below the water tap and push the COLD Cold water flows from the water tap.
WATER switch.
Push the HOT WATER switch Hot water flows from the water tap.
Note: The 3-phase safety-device is a "sleeping" protection device and must be tested for correct operation after
maintenance.
Disconnect the Thermistor and replace it by a Test Thermistor
Connect the electrical power to the coffee maker and set After approximately 2 minutes, the 3-phase safety-device
the ON/OFF switch to ON, cuts off the power to the coffee maker.
Drain the coffee maker with open water system and allow the coffee maker to cool off.
Reset the 3-phase safety device and reconnect the original Thermistor.
Pressure Relief Valve Test
Switch the main Power to on and refill the Coffee Maker. The pressure relief valve opens at:
Close the water system after the Coffee Maker is refilled. 5.6 ± 0.3 bar (82 ± 5 psi).
Allow the Coffee Maker to warm up from cold.
Check the water section and make sure that there are no
leakage.
END OF TEST PROCEDURES
5. FAULT ISOLATION
NOTE: There is no indication if the LED in the indicator fails.
FAULT CAUSE REMEDY
1. Actuated ON/OFF light Defective LED Replace LED

does not come on Defective switch Replace switch.
2. OUT OF ORDER light Defective LED Replace LED.

does not come on Defective switch Replace switch
3. OUT OF ORDER light Tank does not fill. Check the water supply
stays on Check the vent valve
4. Actuated BREW switch Defective LED Replace LED.

Lock-lever not in down Put lock-lever in down
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position. position.
Defective opto-coupler Replace opto-coupler.
Defective level sensor Replace level sensor.
5. BREW READY light Defective LED Replace LED.

6. Leakage at boiler or hoses Seal damaged Replace seal.

Torque at unions too low Adjust torque setting.
7. Water temperature too Incorrect adjustment of Adjust the

high or too low the potentiometer potentiometer R9.
Defective temperature sensor Replace temperature sensor.
8. Coffee server overflows Dirty sensor pins Clean the sensor pins
9.Heating elements do not Power relay defective Replace relay

heat up Tank less than 75 % full Check the water supply
Sticking vent valve Clean the vent valve
Defective heating element Replace the heating element.
Scale on the heating Decalcify the heating
elements elements
(Refer to pageblock 401).
10.Three-ph. safety-device Power relay defective Replace the relay and reset
has turned off total power. the 3-ph safety device.
Defective temperature Replace temperature sensor.
sensor
11. Water flows out of Failure of 3-way tap Check and clean the 3-way
water tap (Effectivity: A) tap.
Failure of the HOT Check and clean the
WATER solenoid valve solenoid valve
(Effectivity: B,C)
Failure of the COLD Check and clean the
WATER solenoid valve solenoid valve.
(Effectivity: B,C)
12. Water flows out of the Failure of vent valve Check and clean vent valve.
vent valve
25-31-24 Page 105

July 1, 1997
MAINTENANCE MANUAL
TEST THE PRINTED CIRCUIT BOARD
6. General
A. This procedure gives instructions to test the Printed Circuit Board (PCB) of the
DA 14 Series Coffee Maker.
B. Test Equipment
The following equipment is necessary to test the PCB:
Part No. Nomenclature

220Vac Power Supply
Test Box
Multimeter
Screw Driver
Instructions
C. Preparation
(1) Put the coffee maker on a bench and remove the cover to get access to the
PCB.
(2) Remove the PCB from the coffee maker.
(3) Put the test box on the bench and connect the electrical power.
CAUTION: MAKE SURE THAT THE SWITCHES "MAIN POWER" AND

"115V" ARE IN THE OFF POSITION BEFORE YOU INSTALL
THE PCB IN THE TEST BOX. DAMAGE TO THE PCB CAN
RESULT.
(4) Install the PCB in the test box. Make sure that the components face the
switches of the control panel.
(5) When you use a 220Vac power supply, it is necessary to connect the test
electrode to the cathode of the diode D6 (Refer to Figure 101).
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July 1, 1997
MAINTENANCE MANUAL
PCB TEST
Figure 101
25-31-24 Page 10712

July 1, 1997
MAINTENANCE MANUAL
(6) Before you start the test, set these switches:
MAIN POWER to ON (The POWER light comes on)

115V to ON (The 115V light comes on)
POWER to OFF
TIME SELECT to LEAK OUT TIME
COFFEE LEVEL to LOW
LOCK to OPEN
WATER LEVEL to HIGH.
D. Procedure
NOTE: Refer to Figure 101 for location of the parts.

The LED "WATER LEVEL HIGH" is not on when 220Vac power is used.
WHERE ACTION RESULT
1 Test box Set the POWER switch to ON The OUT OF ORDER light goes off
The POWER light comes on
The COFFEE LEVEL LOW
light comes on
The LOCK OPEN light comes
on.
2 PCB Connect the positive line of the The voltage must be 12V ± 1V.
multimeter to the positive side of
the capacitor C1.
Connect the negative line to
ground.
Check the voltage accross the
capacitor C1.
3 Test box Turn the TEMP SELECT switch
to the 88 °C position.
4 PCB With a screw driver, slowly The POWER RELAYS light

adjust the potmeter R6 until the goes off.
POWER RELAYS light goes off.
5 Test box Turn the TEMP SELECT switch The POWER RELAYS light
to the 87 °C position. comes on.
7 PCB With a screw driver, slowly The OUT OF ORDER light
adjust the potmeter R10 until the comes on.
OUT OF ORDER light comes on.
8 Test box Turn the TEMP SELECT switch The OUT OF ORDER light
to the 99 °C position. goes off.
The POWER RELAYS light
goes off.
10 PCB With a screw driver, slowly The OUT OF ORDER light

adjust the potmeter R9 until the comes on.
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July 1, 1997
MAINTENANCE MANUAL
WHERE ACTION RESULT

OUT OF ORDER light comes on.
11 Test box Turn the TEMP SELECT switch The OUT OF ORDER light
to the 2 °C position. goes off.
comes on.
12 Test box Repeat steps 3, 5, 6, 8, 9 and 11 The lights must come on and go
off as shown in the
corresponding RESULT column.

14 Test box Set the WATER LEVEL switch The OUT OF ORDER light
to LOW comes on.
The WATER LEVEL LOW
light comes on
to HIGH goes off.
The WATER LEVEL HIGH
light comes on
16 Test box Give a "Brew pulse" - Set the The BREW light does not come
BREW switch quickly to BREW on.
and OFF.
17 Test box Set the LOCK switch to CLOSED. The CLOSED light comes on.
18 Test box Give a "Brew pulse" - Set the The BREW light comes on.
BREW switch quickly to BREW The BREW-VALVE light comes on.
and OFF.
19 Test box Set the 115V switch to OFF The 115V light goes off
The OUT OF ORDER light comes on
The BREW-VALVE light goes off
20 Test box Set the 115V switch to ON The 115V light comes on
The OUT OF ORDER light goes off.
21 Test box Give a "Brew pulse" - Set the The BREW light come on.
BREW switch quickly to BREW and The BREW-VALVE light comes on.
OFF.
22 Test box Set the COFFEE LEVEL switch The WATER LEVEL HIGH
to HIGH. light comes on
The BREW-VALVE light goes
off.
The BREW READY light comes
on.
The digital counter starts
running and stops within 9 to 27
seconds.
23 Test box Set the LOCK switch to OPEN. The LOCK OPEN light comes
on. The BREW READY light goes
off.
24 Test box Turn the TEMP SELECT switch The POWER RELAYS light
to the 87 °C position. comes on.
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July 1, 1997
MAINTENANCE MANUAL
WHERE ACTION RESULT

to LOW comes on.
goes off.
26 Test box Check the water valve. The HOT light comes on.
Set the WATER VALVE switch
to HOT.
27 Test box Set the WATER VALVE switch The COLD light comes on.
to COLD.
(1) Set these switches:
MAIN POWER to OFF
115V to OFF
POWER to OFF
(2) Remove the PCB from the test box.
“END"
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MAINTENANCE MANUAL
DISASSEMBLY
1. General
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 >0001 and up D
This procedure gives instructions to remove parts from the coffee maker until it is completely
disassembled. If necessary, refer to pageblock 101 (Testing and Fault
Isolation) to determine the condition of a component or the cause of its malfunction.
This will help you to determine the extent of disassembly that is required, and
prevents work that is not necessary.
Put each part that is removed from the coffee maker on a clean surface and keep the
parts in the order of removal. Discard O-rings, fiber washers, packings, gaskets, etc.,
when they are removed, and replace them with new items. To make assembly easier,
tag and identify wires before you disconnect them.
Make sure that you put blanking caps on the open ends of pipes and fittings to prevent
contamination. Also put blanking caps on electrical connectors and receptacles to
protect the contacts.
2. Special Tools, Equipment and Materials
(Refer to Pageblock 901)
Item Used For Quantity
7S608998 Removal / Installation of the 1

heating elements of the boiler
assembly
3. IPL References
When reference is made in a paragraph to more than one figure of the Illustrated Parts
List, the Figure and Item numbers will be given between parentheses.
For example: Figure 2, Item 170 is given as (2-170).
Revision 2 25-31-24 Page 301

April 1, 1996
MAINTENANCE MANUAL
4. Disassemble the Coffee Maker
A. Remove the Coffee Server.
B. Remove the Handle
(Refer to IPL, Figure 2)
(1) Remove the screws (25) to remove the handle (140) together with the hinges
(150).
C. Remove the Top Plate
(1) Remove the screws (25) that attach the top plate (130) to the coffee maker.
(2) Remove the top plate (130).
D. Remove the Pillow-Pack Holder-Assembly
(Refer to IPL, Figure 3).
(1) Remove the pillow-pack holder-assembly (130).

(2) If necessary, remove the nuts (60), lock-washers (22) and washers (85) to
remove the plate (140) and the handle (145).
E. Remove the Control Panel (Effectivity: A)
(Refer to IPL, Figures 5A, 6 and 8)
(1) Loosen the set-screw (5A-155) and remove the knob (5A-150) and the spacer
(5A-140).
(2) Disconnect the electrical connector (8-135) from the receptacle (6-380).
(3) Remove the screws (35) to remove the control panel (6-160).
(4) If necessary, disassemble the control panel (Refer to paragraph F).
F. Disassemble the Control Panel (Effectivity: A)
(1) Remove the nuts (62) to remove the printed circuit board (110).
(2) If necessary, remove the other parts from the front panel (100).
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MAINTENANCE MANUAL
G. Remove the Switch Module Assembly (Effectivity: B,C,D)
(1) Disconnect the connector (380).

(2) Remove the screws (35) which attach the switch module assembly (160) to the
side panels and remove the switch module assembly.
H. Disassemble the Coffee Maker
(1) Remove the Locking Assembly
(Effectivity: A,B,C)
(Refer to IPL, Figure 4A)
(a) Remove the screws (35) that attach the hinges (170) to the side panels (100
and 110).
(b) Remove the two screws (35) that attach the lock plate (150) to the left side panel
(100).
(c) Carefully remove the locking assembly (190).
NOTE: Keep the hinges (120) with the locking assembly.
(d) Disconnect the connectors (300) from their receptacles.

(e) If necessary, disassemble the locking assembly [Refer to paragraph (2)].
(Effectivity: D)
(Refer to IPL, Figure 4B)
(f) Remove the screws (25) that attach the locking block (115) to the left side panel.
Move the locking block away from the side panel.
(g) Remove the cable ties which hold the wires to the shaft of the locking
assembly.
(h) Identify, tag and disconnect the two wires.
(i) Remove the screws (25) that attach the hinges (200) to the left and right
side panels.
(j) Remove the server locking assembly.

April 1, 1996
MAINTENANCE MANUAL
(2) Disassemble the Locking Assembly
(a) Remove the lock-nut (180), the spring (170), the handle (160) and the lock
plate (150) from the locking assembly (190).
(b) Remove the screws (5) and the washers (20) to remove the springs (230 and
240) from the cover (220).
(c) Remove the screws (5) and the washers (7 and 20) to disconnect the wires (290)
from the cover (220).
(d) Remove the screws (5) and the washers (20) to remove the cover (220) from
the bracket (210).
(e) Remove the screws (5) and the washers (7 and 20) to remove the brackets
(260 and 270) from the cover (220). Keep the spring (280).
(f) If necessary, remove the brackets (260 and 270), the hinge pins (340) and the
sensor pins (330) from the sensor-pin holder (320).
(3) Remove the Pillow-Pack Rail-Assembly
(Refer to IPL, Figure 3).
(a) Remove the pillow-pack holder-assembly (130).

(b) Remove the nozzle (180) and the fiber washer (170). Discard the fiber
washer.
(c) Remove the screws (27) and the washers (7 and 20) to remove the
pillow-pack rail-assembly (110).
(d) Remove the pillow pack seal (120).
(4) Remove the Lock Assemblies
(a) Remove the screws (25) and remove the primary lock assembly (160).
(b) Remove the screws (25) and remove the secondary lock assembly (170).
(5) Remove the Slide Strips
(a) Remove the screws (25) to remove the slide strips (220 and 230).

April 1, 1996
MAINTENANCE MANUAL
(6) Remove the Water Tap
Effectivity: A,B,C
(a) Remove the screw (25) to remove the clamp (5A-250).

(b) Remove the screws (5A-225) to remove the water tap bracket (5A-220).
(c) Disconnect the water hose (5A-270B) from the pipe (5A-240).
(d) Remove the water tap bracket, together with the water tap (5A-230) and the
pipe from the coffee maker.
(e) If necessary, pull the pipe (5A-240) from the water tap (5A-230). Discard
the O-ring (5A-235).
Effectivity: D
(f) Disconnect the water hose (5A-270B) from the water tap assembly (290).
(g) Remove the screws (225) to remove the water tap assembly (290).
(h) If necessary, remove the aerator (295).
(7) Remove the Right Side Panel
(a) Remove the screws (25) to remove the right side panel (110) from the
brew compartment (100), the connector frame (150) and the PCB frame (270).
(8) Remove the Opto-coupler Operating-mechanism
(a) Remove the nuts (37) and the washers (20 and 55) to remove the bracket
(210).
(b) Remove the screws (25) to remove the guide block (180).
(c) Remove and keep the guide block, bracket, spring (200) and pin (190)
together.
I. Remove the Opto-coupler
(1) Disconnect the connector (390) from the opto-coupler (170).

(2) Remove the screws (2) and washers (42) to remove the opto-coupler.

April 1, 1996
MAINTENANCE MANUAL
J. Remove the Printed Circuit Board (PCB)
(1) Remove the bolt (47) and the washers (55 and 57).
(2) Pull the PCB (300) from the PCB holders (290).
K. Remove the Heating Element of the Brew Compartment
(1) Identify, tag and disconnect the wires connected to the wiring harness.
(2) Remove the nuts (37) and the washers (20 and 55) to remove the cover (260),
the insulation (250) and the heating element (240) from the brew compartment (100).
L. Remove the Switch of the Brew Compartment (Effectivity: A)
(1) Identify, tag and disconnect the wires connected to the wiring harness.
(2) Remove the nuts (50) and the washers (22 and 85) and remove the cable ties
(15).
(3) Remove the nuts (37) and the washers (7 and 20) to remove the switch (230)
and the plate (220) from the brew compartment (100).
M. Disassemble the Wiring Harness
NOTE: Remove only those parts that need to be replaced.
(1) Remove enough cable ties to make the removal of wires to or from
components possible.
(2) Identify, tag and remove the wires connected to the component to be removed.
(3) Remove the nuts (32) and the washers (22 and 85) to remove the 3-way safety-device
(370).
(4) Remove the cover (350), the screws (5) and the washers (20) to remove the terminal
strip (340).
NOTE: Keep the strip (345) with the terminal strip.

April 1, 1996
MAINTENANCE MANUAL
(5) Remove the [screws (42), washers (7 and 20) and nutplate (490)] or the
[screws (42), washers (7 and 20) and nuts (37)] to remove the lock-plate 480), the
spacer (470) and the connector (460).
(6) Remove the attaching parts to remove the relay (330) and the relay socket (440).
(7) Remove the screws (17), the washers (20 and 55) and the nuts (37) to remove the
connector (410).
(8) Use a soldering tool to remove the wires from the capacitors (310) and
remove the attaching parts to remove the capacitors.
(9) Remove the attaching parts to remove the ground wires of the connector (460)
and the ground wires (210A and 210B).
(Effectivity: B,C,D)
(10) Remove the hardware to remove the relay (530) and the relay socket (520).
N. Disassemble the Water System Installation
(Refer to IPL, Figures 5A and 5B)
(1) Remove the 3-Way Tap (Effectivity: A)

(a) If necessary, loosen the set-screw (5A-155) and remove the knob (5A-150) and
the spacer (5A-140).
(b) Disconnect the water hoses (5A-270B, 270C and 270E) and put caps on
the openings.
(c) Loosen the set-screw (5A-135) to remove the shaft assembly (5A-130).
(d) Remove the front nut (77) to remove the tap (5A-120).
(2) Remove the drain plug (5A-190). Put a blanking cap on the fitting.
(3) Remove the pressure relief valve (5A-200). Put a blanking cap on the fitting.
(4) Remove the vent valve assembly (5B-320). Put a blanking cap in the hole.
(5) Remove the Solenoid Valve (Effectivity: A)
(a) Identify, tag and remove the wires connected to the solenoid valve
(5B-290).
(b) Disconnect the water hoses (5B-270A and 5B-270F). Put blanking caps on the
fittings.
NOTE: Keep the restrictor (5B-295) with the solenoid valve.
solenoid valve (5B-290).
(6) Remove the Solenoid Valves (Effectivity: B,C,D)
(a) Identify, tag and remove the wires connected to the solenoid valve
(5B-290).

April 1, 1996
MAINTENANCE MANUAL
(b) Disconnect the water hoses (5B-270A, 270B, 270C and 270F). Put
blanking caps on the fittings.
NOTE: Keep the restrictor (5B-295) with the solenoid valves.
solenoid valves (5B-290) from the bracket (5B-375).
(7) Remove the Temperature Sensor
(a) Identify, tag and disconnect the wires connected to the wiring harness.
(b) Remove the temperature sensor (5B-340). Put a blanking cap in the hole.
(8) Remove the Level Sensor Assembly
(a) Identify, tag and remove the wire from the level sensor assembly (5B-350).
(b) Remove the level sensor assembly. Put a blanking cap in the hole.
(9) Remove the Heating Elements
(a) Identify, tag and disconnect the wires connected to the wiring harness.
(b) Use the removal/installation tool (Refer to page block 901) to remove the heating
elements (5B-450). Discard the O-rings (5B-460).
(c) Put blanking caps in the holes.
(10) Remove the Manifold
(a) Remove the water hoses (5B-270C and 5B-270G) from the manifold
(5B-470).
(b) Remove the manifold. Put blanking caps on the fittings.
(11) Remove the Water Coupling Assembly
(a) Remove the water hose (5B-270G) from the water coupling assembly
(5B-400).
(b) Remove the [screws (42), washers (7 and 20) and nutplate (5B-410)] or the
[screws (42), washers (7 and 20) and nuts (37)] to remove the connector
(5B-400). Put blanking caps on the fittings.
(12) Remove the Drain
(a) Remove the screws (5), the washers (20 and 55) and the nut (37) to remove
the drain (5B-430).
(b) Remove the drain pipe (5B-440).
(13) Remove the Boiler Assembly
(a) Remove the screws (25) to remove the boiler assembly (5B-360) from the
brew compartment (5B-100).
(b) If necessary, remove the insulation (5B-365).

April 1, 1996
MAINTENANCE MANUAL
O. Remove the Connector Frame
(1) Remove the screws (25) to remove the bracket (380) from the left side plate
(390).
P. Remove the PCB Frame
(1) Remove the screw (30) and the washers (22 and 85) to remove the frame
(270) from the frame (140).
Q. Remove the Rear Panel Assembly
(1) Remove the screws (25) to remove the rear panel (370) from the left side
panel (390).
R. Remove the Left Side Panel
(1) Remove the screws (25) to remove the left side panel (110) from the brew
compartment (100).

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
"END"

April 1, 1996
MAINTENANCE MANUAL
CLEANING
1. Introduction
This page block contains the procedures and materials required for cleaning the coffee
maker and the component parts of the unit.
WARNING: REMOVE THE ELECTRICAL POWER BEFORE YOU CLEAN THE

COFFEE MAKER.
WARNING: BE CAREFUL WHEN YOU USE THE CLEANING MATERIALS.

THE CLEANING MATERIALS CAN BE HARMFUL. FOLLOW
THE MANUFACTURER'S HANDLING INSTRUCTIONS.
WARNING: PUT ON GOGGLES WHEN YOU USE A COMPRESSED AIR

SOURCE. WARN OTHER PERSONS TO KEEP CLEAR OF THE
AREA.
CAUTION: DO NOT USE ABRASIVE CLEANING COMPOUNDS ON THE

COFFEE MAKER. THE COMPOUNDS WILL DAMAGE THE
SURFACE OF THE METAL.
Local Adjustable air source 1

0-193 Kpa (0 - 28 psi).
Local Ultra-sonic equipment 1
Local Alcohol-based degreaser A/R
Local Absorbent cloth A/R
Local Detergent A/R
Local Protective gloves A/R
Local Soft bristle brush A/R
Local Inolit 5210 A/R
NOTE: Equivalent substitutes may be used for listed items.

April 1, 1996
MAINTENANCE MANUAL
3. Procedure
A. Clean the Metal Parts
(1) Use the Ultra sonic Equipment, clean water, an absorbent cloth and household
detergent. The cleaning solvent must be clean water with detergent as used for
ordinary household kitchen appliances.
(2) If no Ultra Sonic Equipment is available, remove accumulated dirt with a soft bristle
brush or if necessary use a dry, filtered compressed air source.
(3) When the coffee maker is clean, rinse it with boiling water. Make sure all
parts are dried with clean absorbent cloths or clean brushes and dry, filtered
compressed air.
B. Clean the electrical parts
CAUTION: DO NOT PUT ELECTRICAL PARTS INTO THE CLEANING

SOLUTIONS.
(1) Use clean absorbent cloths to clean all exposed areas.

(2) Use a soft bristle brush to clean inaccessible areas.
(3) Use compressed air to remove dust, dirt and foreign matter from the unit.
C. Decalcify the Coffee Maker
WARNING: THE SOLVENT TO DECALCIFY IS HARMFUL. FOLLOW THE

MANUFACTURER'S INSTRUCTIONS.
(1) If scale has formed inside the coffee maker, use Inolit 5210 or similar to
remove the scale.
NOTE: (a) For a thin scale, use 100 - 150 g (3.5 - 5.3 oz) of the powder in 1 liter
(0,26 US gal) of water at a temperature of 50 °C - 70 °C
(122 °F - 158 °F).
(b) For a thick scale, use 200 - 250 g (7 - 8,8 oz) of the powder in 1 liter
(0,26 US gal) of water at a temperature of 50 °C - 70 °C
(122 °F - 158 °F).

April 1, 1996
MAINTENANCE MANUAL
(2) Fill the coffee maker with the solution and make sure that bubbles of gas
begin to form.
(3) When the bubbles of gas stop to form, remove the solution from the coffee
maker and flush the coffee maker thoroughly 4 or 5 times.
(4) If necessary, repeat steps (1) thru (3).

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
"END"

April 1, 1996
MAINTENANCE MANUAL
CHECK
1. General
The following checks should be carried out at regular intervals, not exceeding 2000
flight hours, to ensure that the coffee maker operates satisfactorily. The quality of the
water that is used will affect the performance of the coffee maker. If the quality of the
water that is regularly used contains impurities, it is recommended that these checks
are carried out more frequently.
Whenever the coffee maker is removed from the aircraft the steps below should be
carried out.
2. Procedure
A. Clean the coffee maker (Refer to pageblock 401).
B. Inspect the coffee maker
(1) Inspect the coffee maker for:
- any obvious damage.

- corrosion on any of the surfaces and in crevices
- cracks in the plastic parts
- discoloration of any of the surfaces. This could indicate excessive
temperatures and the cause must be investigated and the fault corrected.
(2) Visually inspect the electrical installation for:
- loose contacts, discoloration of cables or contacts, or evidence of arcing.
Make sure that:
- the cable ties are secure and the wiring harness does not rub against any
surface.
- that the insulation of the wires is free from damage.
- the printed circuit board is properly attached to the mounting bracket and
that there is no sign of damage or overheating.
C. Make sure the coffee maker operates correctly (Refer to pageblock 101).
"END"

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
“END”

April 1, 1996
MAINTENANCE MANUAL
REPAIR
1. General
A. Any part that is damaged or beyond repair must be replaced. Seals and O-rings
must be discarded when they are removed and replaced by new items when the
coffee maker is assembled.
B. If any wiring needs to be replaced the wire must be made according to

MIL-W-16878D, type EE2007 or EE2019. Make sure that, if any wire is replaced
- the size of the wire is not changed

- the routing of the wiring harness is not changed.
C. Standard practices for the aircraft industry must be used for:
- sheet metal repairs

- replacement of rivets
- replacement of bushings
- replacement of bearings, etc.

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
“END”

April 1, 1996
MAINTENANCE MANUAL
ASSEMBLY AND STORAGE
1. General
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 0001 and up D
Make sure that all components have been cleaned, tested and checked in accordance
with the applicable sections of this manual.
Install new O-rings and seals; do not install used items. Apply Dow Corning 7 release
paste (Refer to Pageblock 901) to O-rings before they are installed.
Individual parts of the coffee maker can be installed, depending on accessibility.
If the coffee maker has been completely disassembled, these steps should be followed
in sequence. For the installation of individual items, refer to the applicable steps.
(Refer to Pageblock 901)
Item Used For Quantity
7S608998 Removal/Installation of the 1

heating elements of the boiler
assembly.
3. IPL References
When reference is made in a paragraph to more than one figure of the Illustrated Parts
List, the Figure and Item numbers will be given between parentheses.
For example: Figure 2, Item 170 is given as (2-170).

April 1, 1996
MAINTENANCE MANUAL
4. Torque Values
NOTE: Unless otherwise specified in the text, the nominal torque values to tighten
the nuts are:
Size of nut Torque value
4-40 UNC 0,5 Nm (4,5 lbf in)

6-32 UNC 1,2 Nm (10,5 lbf in)
8-32 UNC 1,2 Nm (10,5 lbf in)
10-32 UNC 1,8 Nm (15,9 lbf in)
5. Procedure
A. Install Components on the Brew Compartment
(Refer to IPL, Figures 3, 5A and 6)
(1) Put the bracket (3-190) in position on the brew compartment (3-100) and use
the washers (22, 65 and 85) and the nuts (32) to install it.
(2) Put the pillow pack seal (3-120) in position on the brew compartment (3-100)
and use the nozzle (3-180) and a new fiber washer (170) to install it.
(3) Put the 3-way tap (5A-120) in position and use the nut (77) to install it. (Effectivity:
A)
(4) Put the shaft assembly (5A-130) in position on the 3-way tap (5A-120) and use
the set-screw (5A-135) to install it. (Effectivity: A)
(5) Put the opto-coupler (6-170) in position on the brew compartment (6-100) and
use the screws (42) and the washers (2) to install it.
(6) Apply a layer of heat sink compound (Refer to Pageblock 901) to the mating surfaces
of the plate (6-220). (Effectivity: A)
(7) Put the plate (6-220) and the switch (6-230) in position on the brew
compartment (6-100) and use the washers (7 and 20) and the nuts (37) to
install them. (Effectivity: A)
(8) Put the heating element (6-240), the insulation (6-250) and the cover (6-260) in
position on the brew compartment (6-100). Use the nuts (37) and the washers
(20 and 55) to install them.
B. Install Components on the Boiler Assembly
(Refer to IPL, Figures 5A, 5B and 6)
(1) Remove the caps from all openings.

April 1, 1996
MAINTENANCE MANUAL
(2) Put new O-rings (5B-460) on the heating elements (5B-450).

(3) Install the heating elements (5B-450) in the boiler assembly (5B-360).
(4) Use the tool 7S608998 to tighten the heating elements.
(5) Put the manifold (5B-470) in position and tighten the nut of the manifold.
(6) Put the drain plug (5A-190) in position and install it.
(7) Put the vent valve assembly (5B-320) in position with a new seal (5B-320D)
and a new O-ring (5B-330). Tighten the nut (5B-320C).
(8) Install the temperature sensor (5B-340).
(9) Install the level sensor assembly (5B-350).
(10) Install the insulation (5B-365).
(11) Apply a layer of heat sink compound (Refer to Pageblock 901) to the mating surface
of the 3-phase safety-device (6-370).
(12) Put the 3-phase safety-device (6-370) in position and use the nuts (32) and the
washers (22 and 85) to install it.
C. Install Components on the Rear Panel Assembly (Effectivity: A)
(Refer to IPL, Figure 5B and 6)
(1) Put the solenoid valve (5B-290) in position on the rear panel (5B-370) and use
the screws (30) and the washers (22 and 85) to install it.
(2) Put the terminal strip (6-340) in position on the panel (6-140) and use the
screws (5) and washers (22) to install it.
(3) Put the strip (6-345) in position on the terminal strip. (Refer to the Wiring
Diagram in pageblock Description and Operation).
D. Install Components on the Rear Panel Assembly (Effectivity: B,C,D)
(1) If necessary, put the bracket (5B-375) in position and tighten the screws (30).
(2) Put the assembled solenoid valves (5B-290) in position on the rear panel
(5B-370) and use the screws (30) and the washers (22 and 85) to install them.
(3) Put the relay socket (6-520) in position and use the hardware to install it.
(4) Put the relay (6-530) in position and use the hardware to install it .
(5) Put the terminal strip (6-340) in position on the rear panel (5B-370) and use
the screws (5) and washers (22) to install it.
(6) Put the strip (6-345) in position on the terminal strip. (Refer to the Wiring
Diagram in pageblock Description and Operation).

April 1, 1996
MAINTENANCE MANUAL
E. Install Components on the Connector Frame
(1) Install new O-rings (5B-420 and 5B-425) on the water coupling assembly (5B-400).
(2) Put the water coupling assembly (5B-400) in position on the frame (5B-380) and
use the screws (42), the washers (7 and 20) and the nuts (37) or the nutplate
(5B-410) to install it.
(3) Put the connector (6-460), together with the spacer (6-470) and the lockplate (6-480),
in position on the frame (6-150) and use the screws (42), the washers (7 and
20) and the nuts (37) or the nutplate (6-490) to install it.
(4) Put the drain (5B-430) in position and use the screws (5), the washers (20 and 55)
and the nuts (37) to install it.
(5) Put the ground wires of the connector (6-460) and the ground wire (6-210B) in
position on the frame (6-150) and use the bolt (47), the washers (55 and 57) and
the nuts (52) to connect them.
F. Install Components on the PCB Frame
(1) Put the capacitors (310) in position on the frame (270) and use their attaching
parts to install them. Tighten the nuts to 3 lbs in maximum.
(2) Put the PCB holders (290) in position on the PCB frame and press them in
place.
G. Install the Boiler Assembly
(Refer to IPL, Figures 5A and 5B)
(1) Put the boiler assembly (5B-360) in position on the brew compartment (5B-100)
and use the screws (25) to install it.
(2) Connect the water hoses (5A-270C and 5A-270E).
(3) Put the water hose (5A-270D) in position through the hole in the brew compartment.
(4) Put the pressure relief valve (5A-200) in position and install it.

April 1, 1996
MAINTENANCE MANUAL
H. Install the Left Side Panel
(Refer to IPL, Figure 2 and 6)
(1) Put the left side panel (2-110) in position on the brew compartment (2-100)
and use the screws (25) to install it.
(2) Put the slide strip (2-220) in position on the left side panel (2-110) and use the screws
(25) to install it.
(3) Install the Opto-coupler Operating-mechanism
(a) Put the guide block (2-180), the pin (2-190) and the spring (2-200) in
position.
(b) Use the screws (25) to install the guide block.
(c) Put the bracket (2-210) in position and use the nuts (37) and the washers
(20 and 55) to install it.
(4) Put the primary lock assembly (2-160) in position and use the screws (25) to
install it.
(5) Put the ground wire (6-210A) in position and use the bolt (45), the washer
(55) and the nut (52) to install it.
I. Install the Wiring Harness
(Refer to IPL, Figures 5B and 6)

(Refer to the Wiring Diagram in the Description and Operation page block).
(1) Put the wiring harness (6-360) in position at the rear of the brew compartment
(6-100).
(2) Connect the electrical connector (6-390) to the opto-coupler (6-170).
(3) Put the receptacle (6-380) and the springs (6-190) in position and use their attaching
parts to install them.
(4) Connect the wires to the 3-way safety-device (6-370).
(5) Put the wires of the connectors (6-400) for the coffee-server level-sensor
through the holes in the brew compartment (6-100).
(6) Connect the wire to the level sensor assembly (5B-350).
(7) Connect the wires of the temperature sensor (5B-340).
J. Install the Rear Panel Assembly
(1) Put the rear panel (370) in position on the left side panel (390) and use the
screws (25) to install it.

April 1, 1996
MAINTENANCE MANUAL
(Effectivity: A)
(2) Put the restrictor (295) in the union (300) and connect the water hoses (270A
and 270F)(See also Figure 5A).
(Effectivity: B,C,D)
(3) Put the restrictor (295) in the elbow fitting (310) and connect the water hoses (270A,
270B, 270C and 270F)(See also Figure 5A).
K. Install the PCB Frame
(1) Put the PCB frame (270) in position on the brew compartment (100) and the
rear panel (140).
(2) Use the screws (25) to install the PCB frame to the brew compartment.
(3) Use the screws (30) and the washers (22 and 85) to install the PCB frame to the
rear panel.
L. Install Components on the PCB Frame
(1) Put the insulation plate (6-280) in position.

(2) Put the printed circuit board (6-300) in position and use the washers (55 and
57) and the bolt (47) to install it.
(3) Put the ground wire (6-450) in position and use the bolt (52), the washers (2
and 5) and the nuts (25 and 51) to install it.
(4) Use a soldering tool to connect the wires of the wiring harness to the solenoid
valve (5B-290).
(5) Use a soldering tool to connect the wires of the wiring harness to the
capacitors (6-310).
(6) Use a soldering tool to connect the wires of the wiring harness to the switch (6-230).
(Effectivity: A)
(7) Use the cable ties (15), the washers (57 and 85) and the nuts (32) to install the wiring
harness.
(8) Put the connector (6-410) in position on the frame (6-270) and use the screws
(17), the washers (20 and 55) and the nuts (37) to install it.
(9) Put the relay socket (6-440) and the relay (6-330) in position on the frame
(6-270) and use their attaching parts to install them.
(10) Put the wires of the wiring harness and those of the three heating elements and
the strip (6-345) in position on the terminal strip (6-340) and use the attaching
parts to install them.

April 1, 1996
MAINTENANCE MANUAL
(11) Install the cover (6-350) on the terminal strip (6-340).

(12) Connect the wires of the heating-element (6-240) to the wiring harness.
(13) Put the ground wire in position on top of the brew compartment (100) and use
the washer (22 and 85) and the nut (32) to connect it.
M. Install the Connector Frame
(1) Put the connector frame (5B-380) in position on the left side panel (390) and use
the screws (25) to install it.
(2) Connect the water hose (5B-270G) to the connector (5B-400).
(3) Put the ground wires (6-210A and 6-210B) in position on the brew
compartment (6-100) and use the washers (22 and 85) and the nut (50) to
connect them.
(4) Connect the drain pipe (6-440) to the drain of the brew compartment.
N. Assemble the Control Panel (Effectivity: A)
(1) Put the brackets (105), the washers (115), the spacers (120 and 125), the key
tops (130) and the printed circuit board (110) in position on the front panel
(100) and use the nuts (47) to install them.
O. Install the Control Panel
(Refer to IPL, Figures 5A, 6 and 8)
(1) Put the control panel (6-160) in position and use the screws (25) to install it.
(2) Connect the electrical connector (8-135) to the receptacle (6-380).
(Effectivity: A)
(3) Put the spacer (5A-140) and the knob (5A-150) on the shaft (5A-130) and use
the set-screw (5A-155) to install the knob.

April 1, 1996
MAINTENANCE MANUAL
P. Install the Right Side Panel
(Refer to IPL, Figures 2 and 6)
(1) Put the right side panel (2-120) in position and use the screws (25) to install it to
the brew compartment (2-100), the control panel (6-160), the PCB frame (6-270) and
the connector frame (6-150).
(2) Put the secondary lock (2-170) in position and use the screw (25) to install it.
(3) Put the slide strip (2-230) in position on the right side panel (120) and use the screws
(25) to install it.
Q. Install the Water Tap
Effectivity: A,B,C
(1) Put a new O-ring (235) in the water tap (230).
(2) Put the water tap bracket (220), together with the water tap (230), the pipe
(240) and the water hose (270B) in position.
(3) Use the screws (25) to install the water tap bracket (220).
(4) Use the screw (25) to install the clamp (250).
Connect the water hose (270B) to the 3-way tap (120).
Effectivity: D
(5) Put the water tap assembly (290), together with the aerator (295), in position.
(6) Use the screws (25) to install the water tap assembly (290).
(7) Connect the water hose (270B) to the water tap assembly.
R. Install the Pillow-pack Rail-assembly
(1) Put the pillow-pack rail-assembly (110) in position and use the screws (27)
and the washers (7 and 20) to install it.
S. Assemble the Locking Assembly
(1) Put the brackets (260 and 270), together with the spring (280), the hinge pins (340),
the sensor holder (320) and the sensor pins (330) in position on the cover
(220).

April 1, 1996
MAINTENANCE MANUAL
(2) Use the screws (5) and the washers (7 and 20) to install the brackets (260 and
270) on the cover (220).
(3) Put the bracket (210) in position on the locking arm (200).
(4) Use the screws (5) and the washers (20) to install the cover (220) on the
bracket (210) .
(5) Use the screws (5) and the washers (7 and 20) to connect the wires (290) to
the cover (220).
(6) Put the springs (230 and 240) in position and use the screws (5) and the
washers (20) to install them on the cover (220).
(7) Put the lock plate (150) in position on the locking arm (200).
(8) Put the handle (160) together with the handle guide (165) in position on the
locking arm (200).
(9) Put the spring (170) in position on the locking arm (200) and use the lock-nut
(180) to install it.
(10) Put the springs (130 and 140) in position on the locking arm (200).
(11) Put the hinges (120) in position on the locking arm (200).
T. Install the Locking Assembly
(1) Put the locking assembly (190), together with the springs (130 and 140), in
position between the side panels.
(2) Use the screws (35) to install the hinges (120).
(3) Put the lock plate (150) in position on the left side panel and use the screws
(35) to install it.
(4) Connect the electrical wires (290).(Refer to the Wiring Diagram in the
Description and Operation page block).
(Effectivity: D)
(5) Put the locking assembly, together with the spring (210), in position between
the side panels.
(6) Use the screws (35) to install the hinges (200).
(7) Put the locking block (115) in position on the left side panel and use the
screws (25) to install it.
(8) Connect the electrical wires. (Refer to the Wiring Diagram in the Description
and Operation page block).
U. Do a test of the coffee maker (Refer to Pageblock 101).

April 1, 1996
MAINTENANCE MANUAL
V. Make the Coffee Maker Serviceable
(Refer to IPL, Figures 2 and 3)
(1) Put the top plate (2-130) in position and install it with the screws (25).
(2) Put the handle (2-140) together with the hinges (2-150) in position and use the screws
(25) to install them.
(3) Install the pillow-pack holder-assembly (3-130).
(4) Install the coffee server (3-160).
6. Storage Instructions
A. Storage of the coffee maker under clean and dry atmospheric conditions is
unlimited. Before you put the coffee maker into storage, you must:
- Do a complete test of the coffee maker. Identify and rectify faults

(Refer to pageblock 101)
- Thoroughly clean the coffee maker (Refer to pageblock 401).
- Put blanking caps on the electrical connector and the water coupling.
- Keep the coffee maker in the ATA 300, cat. II container in which it was
delivered.
"END"

April 1, 1996
MAINTENANCE MANUAL
FITS AND CLEARANCES

1. General
There are no special fits and clearances applicable for this coffee maker.

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
“END”

April 1, 1996
MAINTENANCE MANUAL
SPECIAL TOOLS, EQUIPMENT AND MATERIALS
1. Introduction
This pageblock gives a list of the special tools, equipment and materials that are
necessary to do the maintenance tasks given in this manual.
NOTE: Equivalent substitutes may be used for listed items.
2. Special Tools and Materials
INVENTUM NOMENCLATURE QTY VENDOR UTILIZATION

PART NO. CODE T D C C R A
E I L H E S
OR S S E E P S
T A A C A Y
VENDOR I S N K I /
PART NO. N S I R S
G Y N T
G O
R
E
7S608998 Removal/Installation 1 X X
Tool
7S610015 Lens Tool X X
7S610016 LED Tool X X
Local Adjustable Air Source 1 X
Local Hot Air Source 1 X
Local Ultra-sonic Cleaning 1 X
Equipment
Local Detergent A/R X
Local Degreaser, Alcohol-based A/R X
Local Absorbent cloth A/R X
Local Blanking caps A/R X
Local Multi-meter 1 X
Local Inolit 5210 A/R X
Dow Corning 7 Release Paste A/R X
Dow Corning Heat Sink Compound A/R X
340

April 1, 1996
MAINTENANCE MANUAL
3. Availability
The special tools are available from:
Royal Inventum Company

PO Box 1152
3430 BD Nieuwegein
The Netherlands
Telephone 3402 29200

Fax 3402 36949
Removal / Installation Tool 7S608998

Figure 901
Lens Tool - 7S610015

Figure 902
LED Tool - 7S610016

Figure 903
“END”
Page 902 25-31-24

MAINTENANCE MANUAL
ILLUSTRATED PARTS LIST
1. Introduction
A. General
This Illustrated Parts List (IPL) gives a list of components used on the following
Coffee Makers:
DA 24 72012400 0001 to 0199 A

DA 24 72012400 0200 and up B
DA 24 72012410 0001 and up C
DA 24 72012420 0001 and up D
Mounting Rail, optional:
Part Number Effectivity
7S609609 X
7S609642 Y
7S609669 Z
B. How to use the IPL
The parts list when used in conjunction with the accompanying illustrations will
help identify all parts and will make disassembly and assembly easier.
The illustrations show the replaceable items in the unit. These items are given
numbers. Dashes ( -- ) in front of the item number means that the item is not
shown on the illustration.
Section 6 shows a table of equipment designators for electrical components.
C. Views
The Left Hand (LH) and Right Hand (RH) are determined when you stand in front
of the coffee maker and see the control switches.
25-31-24 IPL Page 1001

MAINTENANCE MANUAL
The Detailed Parts Lists have:
- FIG. ITEM numbers, given in an increasing sequence

- PART NUMBER, to identify the parts by number
- AIRLINE PART NO, for use by airlines
- NOMENCLATURE, to identify parts by name and indented to show
the relationship of items (see Paragraph 2). Vendor codes
(when applicable), identified by a "V" and the vendor code number,
according to "Federal Supply Code for Manufacturers".
- EFF. CODE, to find the applicability of parts in the different versions of
coffee makers
- UNITS / ASSY, to find the quantity of items.
2. Lay-out
The parts list is laid out to show the relationship between the parts.
1234567
Assembly or Installation Assembly (RF) number
Attaching parts for assembly or Installation of RF Assembly
*****
. Detail parts forming the assembly
. Sub-assembly
Attaching parts for the sub-assembly
*****
. . Detail parts forming the sub-assembly
. . Sub-sub assembly
Attaching parts for the sub-sub assembly
*****
3. Abbreviations
-Assy Assembly
-AR As required
-Eff Effectivity Code
-FIG Figure
-IVT Inventum
-LH Left Hand, as you view the front
-PN Part Number
-RF Reference
-RH Right Hand, as you view the front
-NP Non Procurable
IPL Page 1002 25-31-24 Revision 2

April 1, 1996
MAINTENANCE MANUAL
4. Part numbers and Item numbers
A. Part Numbers
Even though many off-the-shelf parts are available, only certain items have proved
to comply with the INVENTUM high standards. In order to have control of the
quality of these items that are important for the correct operation of the
component, the Inventum part number is given, rather than the standard part
number.
B. Item Numbers
The numbers 2 to 99 are reserved for standard hardware and are unique for these
items.
Throughout the IPL, eg: the nut 7S235610 (MS35649-262) is Item No. 52,
the washer 7S341080 (AN960C-8) is Item No. 85, etc.
Attaching parts are listed below the parts they attach.
C. Cross-Reference and Index of Standard Hardware
The table in the cross-reference and index of standard hardware (Paragraph 7)

shows the relationship between Inventum part numbers and other standard
numbers.
5. Vendors
Parts manufactured by companies other than INVENTUM are incidentally identified

by an appropriate vendor code, following the nomenclature and are preceded by
the letter "V". Standard parts, such as AN, MS, etc. are not identified by a vendor code.
25-31-24 IPL Page 1003

MAINTENANCE MANUAL
6. Equipment Designator Index
EQUIPMENT DESIGNATOR NOMENCLATURE FIGURE/ ITEM NO.
B1 3-Phase Safety-device 6 - 370
C 21 thru C24 Capacitor 6 - 310
D1, 2 Diode 6 - 430
H1 thru H3 Heating Element (Boiler) 5B - 450
H4 Heating Element (Server) 6 - 240
J1 Connector to the PCB 6 - 410
J2 Connector to the 6 - 380

Control panel / Switch module
J3 Terminal Strip 6 - 340
J4 Connector to Aircraft Electrical 6 - 460

System
K1 Relay 6 - 330
K2 Eff: B,C,D Relay 6 - 530
LS1 Level Sensor (Boiler) 5B - 350
LS2 Level Sensor (Server) 4
S3 Opto-coupler 6 - 170
S4 Eff: A Switch 6 - 230
T1 Temperature Sensor 5B - 340
V1, 2, 3 Solenoid Valve 5B - 290B

April 1, 1996
MAINTENANCE MANUAL
7. Cross Reference and Index of Standard Hardware
NOTE: Due to different effectivities, it is necessary to refer to the Figure and Item
number for quantity requirements.
INVENTUM NOMENCLATURE STANDARD DETAILS FIG. ITEM

PART No.
7S201235 WASHER 6, 7A, 11, 2

14
7S234530 SCREW MS51957-14 4-40 UNC-2A 4A, 5B, 6 5
CRS
7S234650 WASHER DIN 125A 7x3.2x0.5 mm 3, 4A, 4B, 7
5B, 6, 10
7S234683 ANCHOR-NUT 2, 5B, 6, 10
7S235283 CABLE TIE 6, 14 12
7S235284 CABLE TIE 6 15
7S235358 SCREW MS51657-18 6, 10, 11 17
7S235426 WASHER 12 18
7S235427 NUT 12 19
7S235545 LOCK-WASHER MS35338-136 2, 3, 4A, 4B 20`
5B, 6, 7A
11, 14
7S235547 LOCK-WASHER MS35338-137 2, 3, 5B 22
6, 10
7S235550 SCREW MS24693C49 2, 4B, 5A, 25
5B, 6
7S235553 SCREW MS51957-15 3 27
7S235555 SCREW MS51957-43 5B 30
7S235556 NUT MS35649-284 2, 3, 6 32
7S235557 SCREW MS24693C47 4A, 6 35
7S235558 NUT MS35649-244 4-40 UNJC-3B 2, 5B, 6, 11, 37
CRS 14
7S235562 SCREW MS51957-41 40
7S235565 SCREW MS51957-17 5B, 6 42
7S235603 BOLT NAS1096-1-6 6 45
7S235604 BOLT NAS1096-1-8 6 47
7S235608 NUT NAS679S-08 6 50
25-31-24 IPL Page 1005

MAINTENANCE MANUAL
INVENTUM NOMENCLATURE STANDARD DETAILS FIG. ITEM

PART No.
7S201235 WASHER 6, 7A, 11, 2

14
7S235609 NUT NAS679A06W 6 51
7S235610 NUT MS35649-262 6 52
7S235611 WASHER AN960C6L 2, 5B, 6 55
7S235612 LOCK-WASHER AN935-6L 6 57
7S235721 NUT 3 60
7S235770 NUT NAS679C04W 8, 10, 11 62
7S235979 RIVNUT 5B 63
7S235980 RIVNUT 5B 64
7S236003 WASHER 3 65
7S236116 WASHER 10 67
7S236242 SCREW 7A 70
7S236431 SCREW MS51957-46 10 71
7S236432 NUT 10 72
7S236433 WASHER 10 75
7S236462 SCREW 10 77
7S236572 NUT MS20500-1032 10 80
7S236666 NUT 5A 82
7S237125 NUT 3 83
7S341080 WASHER AN960C8 2, 3, 5B, 85
6, 10
7S341252 LOCK-WASHER 10 87
7S342536 BLIND RIVET 5B, 6 88
7S342538 BLIND RIVET 2 90
7S371003 NUT 4B, 7A 92
7S371105 SCREW 7A 95

April 1, 1996
MAINTENANCE MANUAL
8. Numerical Index
PART NOMENCLATURE AIRLINE PART FIGURE ITEM TOTAL

NUMBER NUMBER
7S201235 WASHER 8 115 6

7S201777 FIBER WASHER 3 170 1
7S201945 O-RING 5B 330 1
7S220122 SPIRAP 6 365 45 cm
(18 in)
7S234019 O-RING 5B 425 1
7S234492 TERMINAL 6 500 10
7S234493 TERMINAL 4A 295 2
7S234496 TERMINAL 6 510 6
7S234790 SPIRAL WRAP 14 160 AR
7S234803 AERATOR 5A 295 1
7S234848 GROMMET 6 200 2
7S234906 ELECTRICAL WIRE 4A 290 25 cm
(10 in)
6 366A 990 cm
(390 in)
7S234907 ELECTRICAL WIRE 6 367 50 cm
(20 in)
10 120 200 cm
(79 in)
7S234908 ELECTRICAL WIRE 6 368 420 cm
(166 in)
7S234912 CAPACITOR 7B 520 1
7S235020 DELETED
7S235041 RELAY 6 330 1
7S235044 RELAY SOCKET ASSY 6 440 1
7S235047 RELAY 6 530 1
7S235051 RELAY SOCKET ASSY 6 520 1
7S235062 O-RING 5B 460 3
7S235075 3-PHASE 6 370 1
SAFETY-DEVICE
7S235082 THERMOSTAT 6 230 1
7S235120 PRESSURE RELIEF 5A 200 1
VALVE
7S235122 GROMMET 6 320 1
7S235365 HANDLE 3 145B 1
25-31-24 IPL Page 1007

MAINTENANCE MANUAL

NUMBER NUMBER
7S235367 NOZZLE 3 180 1

7S235485 O-RING 10 180 1
7S235489 O-RING 5A 235 1
7S235495 INSULATOR 4B 120 2
7S235496 ROD, CONDUCTOR 4B 150 2
7S235497 INSULATOR 4B 140 2
7S235498 LEVEL SENSOR 4B 170 1
7S235499 LEVEL SENSOR 4B 180 1
7S235505 COVER 4B 130 1
7S235649 INSULATION HOSE 4B 160 6 cm
(2,5 in)
7S235652 SHRINKABLE TUBING 4A 205 10 cm
(4 in)
4B 190 20cm
(7,9 in)
7S235659 HOSE 5A 270 120 cm
5B (48 in)
7S235664 UNION 5B 300 1
7S235666 ELBOW FITTING 5B 310 1
7S235694 CABLE 6 305 1
7S235709 CONNECTOR 6 460A 1
7S235722 SLEEVE 5A 281 7
5B 2
7S235723 NUT 5A 282 7
5B 2
7S235725 CAP 5A 285 1
7S235795 PCB HOLDER 6 290 2
7S235803 NUT 5B 320C NP
7S235804 HOSE NIPPLE 5B 320B NP
7S235806 LEVEL SENSOR 5B 350B 1
7S235807 INSULATION SLEEVE 5B 350A 1
7S235848 CRIMP-SNAP 6 395 5
7S235851 CONNECTOR HOUSING 6 400 4
7S235852 CONNECTOR PIN 6 405 4
7S235853 CONNECTOR 4A 300 2
7S235854 CONNECTOR-PIN 4A 310 2
7S235884 SPRING 2 200 1

April 1, 1996
MAINTENANCE MANUAL

NUMBER NUMBER
7S235904 CAPACITOR 6 310 4

7S235911 COFFEE SERVER 3 160 1
7S235915 HANDLE 4B 100 1
7S235917 LOCK-NUT 4A 180 1
4B 105 1
7S235918 SPRING 4A 170 1
4B 110 1
7S235921 GROMMET 5A 210 1
7S235930 CLAMP 5A 275 4
5B 275 1
7S235962 LOCKING BLOCK 4B 115 1
7S235991 TRANSFORMER 7A 110 1
7S235995 RESTRICTOR 5B 295 1
7S236062 DRAIN PIPE 5B 440 1
7S236098 INSULATION 5B 365 1
7S236099 INSULATION 6 250A 1
7S236167 SWITCH 9 195 3
7S236228 CLAMP-SET 8 140 1
14 125 1
7S236240 PRINTED CIRCUIT BOARD 7A 100 1
ASSY
7S236246 BALL 5B 320E NP
7S236340 HOUSING 5B 320A NP
7S236341 SPACER 5B 320F NP
7S236420 DELETED
7S236421 DELETED
7S236422 DELETED
7S236423 DELETED
7S236424 DELETED
7S236425 DELETED
7S236426 DELETED
7S236427 DELETED
7S236434 PIN 10 190 1
7S236435 NIPPLE 10 150 1
7S236436 NIPPLE 10 130 1
7S236440 COVER 4A 220A 1
7S236442 HEATING ELEMENT 6 240 1
25-31-24 IPL Page 1009

MAINTENANCE MANUAL

NUMBER NUMBER
7S236443 HANDLE 3 145A 1

7S236444 SOCKET 8 136 15
7S236448 CONNECTOR 8 135 1
14 120 1
7S236450 HINGE 2 150 2
7S236453 SET-SCREW 5A 155 1
7S236455 CONNECTOR 10 170 1
7S236458 KEYING PLUG 6 415 1
7S236459 CONTACT 6 420 25
7S236470 CONNECTOR 6 410 1
7S236472 SENSOR- PIN HOLDER 4A 320 1
7S236476 SENSOR-PIN 4A 330 2
7S236478 HINGE-PIN 4A 340 2
7S236480 SLIDE STRIP, LH 2 220 1
7S236481 3-WAY TAP 5A 120 1
7S236483 SPRING, LH 4A 230 1
7S236484 SPRING, RH 4A 240 1
7S236491 RECEPTACLE 6 380 1
7S236492 SOCKET 6 385 15
7S236507 SET-SCREW 3 115 1
7S236508 SET-SCREW 3 116 1
5A 135 1
7S236560 SPRING-SET 6 190 1
11 145 1
7S236628 HINGE 4A 120 2
4B 200 2
7S236629 GUIDE BLOCK 2 180 1
7S236648 SPACER 9 105 10
7S236649 BOARD 9 100 1
7S236654 DRAIN NIPPLE 10 140A 1
7S236655 SPACER 8 120 4
7S236657 SPACER 8 125 4
11 155 2
7S236658 O-RING 10 160 1
7S236664 KNOB 5A 150 1

April 1, 1996
MAINTENANCE MANUAL

NUMBER NUMBER
7S236665 SPACER 5A 140 1

8 120 4
7S236667 INSERT 5A 280 7
5B 280 1
7S236669 SPACER 6 470 1
7S236671 LOCK PLATE 4A 150A 1
7S236672 WATER TAP BRACKET 5A 220A 1
7S236676 SPRING 4A 280 12
7S236705 TERMINAL STRIP 6 340A 1
7S236706 TERMINAL STRIP 6 340B 1
7S236715 COVER 6 350A 1
7S236716 COVER 6 350B 1
7S236728 O-RING 5B 420 1
7S236804 PIN 5B 320G 1
7S236805 SLIDE STRIP, RH 2 230 1
7S236924 RELAY 9 190 2
7S237018 INSULATION 6 250B 1
7S237136 DRAIN NIPPLE 10 140B 1
7S237141 GUIDE, HANDLE 4A 165 1
7S237152 WATER TAP BRACKET 5A 220B 1
7S237169 COVER 4A 220B 1
7S237188 STUD 14 165 2
7S237233 CONNECTOR 11 140 4
14 110 2
7S237234 CONNECTOR 11 170 1
14 115 3
7S237235 ELEMENT 11 130A 1
14 215 1
7S237236 ELEMENT 11 130B 3
14 220 1
7S237237 ELEMENT 11 165 3
14 240 3
7S237239 ELEMENT 14 220 1
7S237240 SEAL 5B 320D NP
7S237242 SWITCH ELEMENT 11 135A 1
25-31-24 IPL Page 1011

MAINTENANCE MANUAL
PART NOMENCLATURE AIRLINE PART FIGURE ITEM TOTA

NUMBER NUMBER L
7S237243 SWITCH ELEMENT 11 135B 3

14 235 1
7S237245 FRAME 11 120 7
14 205 5
7S237247 LOCK-RING 11 125 7
14 210 5
7S237250 LENS, ON/OFF 11 115A 1
14 175 1
7S237251 LENS, WATER IS HOT 11 115C 1
14 195 1
7S237252 LENS, HOT WATER 11 115D 1
7S237253 LENS, COLD WATER 11 115E 1
7S237254 LENS, BREW 11 115F 1
14 185 1
7S237255 LENS, NO WATER? 11 115B 1
OUT OF WATER 14 180 1
7S237256 LENS, BREW READY 11 115G 1
14 190 1
7S237259 LED, YELLOW 11 160 5
DELETED 14 200 5
(Pre SB DA24-25-14)
7S237260 CONNECTOR 11 150 1
7S237265 COVER 11 175 4
7S238057 TRANSISTOR 7A 150 5
7S238058 TRANSISTOR 7A 250 1
7S238060 MOS NFET 9 180 1
7S238100 FET OPTOCOUPLER 9 175 2
7S238114 INTEGRATED 7A 180 3
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
CIRCUIT
7S238301 DIODE 7A 120 10

April 1, 1996
MAINTENANCE MANUAL

NUMBER NUMBER L
7S238302 DIODE 7A 170 1

7S238307 DIODE 6 430 1
9 145 12
7S238309 ZENER 9 165 2
7S238316 DIODE 7A 240 2
7S238318 DIODE 7A 130 1
7S238319 ZENER DIODE 7A 140 1
7S238320 ZENER DIODE 7A 160 1
7S238321 LED, YELLOW 9 150 2
7S238322 LED, RED 9 155 2
7S238330 LED, GREEN 9 160 2
7S238331 ZENER 9 170 1
7S238399 7 SEGM. DISPLAY 9 185 2
7S238517 CAPACITOR 7B 280 13
7S238533 CAPACITOR 9 135 3
7S238534 CAPACITOR 9 140 4
7S238610 RESISTOR 7B 260 6
7S238614 RESISTOR 7B 430 3
7S238615 RESISTOR 7B 440 1
7S238616 RESISTOR 14 140 2
7S238620 RESISTOR 7B 450 4
7S238625 RESISTOR 7B 330 1
7S238628 RESISTOR 7B 350 3
7S238660 RESISTOR 7B 310 1
7S238662 RESISTOR 7B 420 1
7S238664 RESISTOR 7B 410 2
7S238666 RESISTOR 7B 270 5
7S238667 RESISTOR 7B 400 4
7S238668 RESISTOR 7B 360 1
7S238671 RESISTOR 7B 340 2
7S238673 RESISTOR 7B 380 1
25-31-24 IPL Page 1013

MAINTENANCE MANUAL

NUMBER NUMBER
7S238674 RESISTOR 7B 500 1

7S238678 RESISTOR 7B 490 1
7S238680 RESISTOR 7B 370 2
7S238681 RESISTOR 7B 390 1
7S238682 RESISTOR 7B 480 1
7S238683 RESISTOR 7B 320 1
7S238685 RESISTOR 9 120 2
7S238686 RESISTOR 9 110 2
7S238700 RESISTOR 9 115 1
7S238701 RESISTOR 9 125 4
7S238702 SILRES 9 200 1
7S238703 SILRES 9 205 4
7S238780 RESISTOR 9 130 1
7S239039 SPRING, LH 4A 130 1
7S239040 SPRING, RH 4A 140 1
4B 210 1
7S239043 LOCK PLATE 4A 150B 1
7S239061 CONNECTOR 6 460B 1
7S239063 STICKER 2 175 1
7S239072 ELECTRICAL WIRE 6 366B AR
14 155
7S239073 PLACARD 11 180 1
7S239075 PRINTED CIRCUIT 11 100 1
BOARD ASSY
7S239076 FRONT PLATE 11 110 1
7S239107 SOLENOID VALVE 5B 290B 3
7S239118 PLUNGER 12 120B 1
7S239119 SPACER 6 470A 1
7S239120 O-RING 12 110B 1
7S239132 SWITCH ELEMENT 14 230 1
7S239150 BOARD 14 105 1
7S239151 FRONT PLATE 14 170 1
7S239152 PLACARD 14 245 1
7S239153 CONTACT-HOUSING 14 135 2
7S239154 CONTACT 14 130 2
7S239158 STUD 14 165 2
7S239171 ZEN DIODE 14 150 1

April 1, 1996
MAINTENANCE MANUAL

NUMBER NUMBER L
7S239189 REPAIR KIT 12
7S239194 RESISTOR 14 145 1
7S239581 LED RED 14 200A 1
11 160A
7S239582 LED YELLOW 14 200B 3
11 160B
7S239583 LED GREEN 14 200C 1
11 160C
7S348385 PARALLEL CONNECTOR 6 435 2
7S608059 STRIP 6 345 1
7S609005 WATER COUPLING 5B 400 1
ASSEMBLY
7S609098 INSULATION 3 140A 1
7S609112 OPTO COUPLER 6 170 1
7S609170 PIN ASSY 2 190 1
7S609172 BRACKET 2 210 1
7S609229 WIRING HARNESS 6 360A 1
7S609285 PRINTED CIRCUIT BOARD 6 300A 1
ASSY
7S609289 TEMPERATURE SENSOR 5B 340 1
7S609327 PILLOW PACK HOLDER 3 130B 1
7S609328 PILLOW PACK HOLDER 3 150 1
7S609329 SEAL ASSY 3 120 1
7S609333 PILLOW PACK HOLDER 3 130A 1
ASSEMBLY
7S609344 T-FITTING 5B 305 2
7S609409 HEAT-CONDUCTING PLATE 6 220 1
7S609572 CONNECTOR 6 390 1
7S609609 MOUNTING RAIL ASSEMBLY 10 1
7S609624 PRIMARY LOCK ASSEMBLY 2 160 1
7S609625 DRAIN 5B 430 1
7S609626 BRACKET 3 190 1
7S609627 COVER 6 260A 1
Superseded
7S609629 GUIDE BLOCK 2 180A RF
Superseded
7S609632 SCREW 5A 225 4
7S609634 LOCK PLATE 6 480 1
7S609635 MOUNTING RAIL 10 100 1
7S609636 GROUND WIRE 6 210 2
25-31-24 IPL Page 1015

MAINTENANCE MANUAL

NUMBER NUMBER
7S609638 SECONDARY LOCK 2 170 1
ASSEMBLY
7S609640 BREW COMPARTMENT 2 100A 1
7S609641 BRACKET 8 105 2
7S609642 MOUNTING RAIL 10 1
ASSEMBLY
7S609645 LOCKING ARM 4A 200A 1
7S609646 LOCKING ASSY 2 240A 1
BOARD ASSY
7S609655 HANDLE 4A 160A 1
7S609660 BOILER ASSY 5A 110 1
7S609661 HEATING ELEMENT 5B 450 3
7S609664 COVER 6 260B 1
7S609665 TOP PLATE 2 130B 1
7S609666 HANDLE 2 140 1
7S609667 BRACKET, RH 4A 270A 1
7S609669 MOUNTING RACK 10 1
ASSEMBLY
7S609670 PILLOW PACK RAIL 3 110 1
ASSEMBLY
7S609675 FRAME, PCB 6 270 1
7S609676 REAR PANEL ASSY 5B 370A 1
7S609677 FRAME, CONNECTOR 5B 380 1
7S609679 SHAFT ASSY 5A 130 1
7S609680 SIDE PANEL, RH 2 120A 1
7S609681 SIDE PANEL, LH 2 110A 1
7S609682 WATER TAP 5A 230 1
7S609684 CLAMP 5A 250 1
7S609686 PIPE 5A 240 1
7S609687 BRACKET, LH 4A 260A 1
7S609688 DRAIN PLUG 5A 190 1
7S609690 MANIFOLD 5B 470 1
7S609694 FRONT PANEL 8 100 1
7S609802 VENT VALVE ASSY 5B 320 NP
7S609980 WATER COUPLING 10 110A 1
ASSEMBLY

April 1, 1996
MAINTENANCE MANUAL

NUMBER NUMBER
7S609982 NUT PLATE 6 490 1

Superseded
7S609983 INSULATION PLATE 6 280 1
7S609985 WATER COUPLING 10 110B 1
ASSEMBLY
7S609995 NUTPLATE 5B 410 1
Superseded
7S610005 CONTROL PANEL 6 160A NP
7S610122 BREW COMPARTMENT 2 100B 1
7S610123 TOP PLATE 2 130C 1
7S610126 SIDE PANEL, RH 2 120B 1
7S610127 SIDE PANEL , LH 2 110B 1
7S610130 HANDLE 4A 160B 1
7S610139 WATER COUPLING 10 110C 1
ASSEMBLY
7S610157 BRACKET, RH 4A 270B 1
7S610158 BRACKET, LH 4A 260B 1
7S610160 BRACKET 4A 210 1
7S610923 VENT VALVE ASSY 5B 320B 1
7S610948 PLATE 3 140 1
7S610958 LEVEL SENSOR ASSY 5B 350 1
7S610989 BRACKET 5B 375 1
7S610990 REAR PANEL ASSY 5B 370B 1
7S610994 SWITCH MODULE 6 160B NP
ASSEMBLY
7S610995 TOP PLATE 2 130D 1
7S610997 SIDE PANEL, LH 2 120C 1
7S610998 SIDE PANEL, RH 2 110C 1
7S610999 BREW COMPARTMENT 2 100C 1
7S611000 WIRING HARNESS 6 360B 1
7S611007 LOCKING ASSY 2 240B 1
7S611008 LOCKING ARM 4A 200B 1
7S611020 SIDE PANEL, RH 2 120D 1
7S611038 WATER TAP ASSY 5A 290 1`
7S611039 LOCKING ASSY 2 240C 1
7S611047 CONTROL PANEL 6 160B 1
7S611049 BRACKET 3 190B 1
25-31-24 IPL Page 1017

MAINTENANCE MANUAL

NUMBER NUMBER

BOARD ASSY
7S611058 PRINTED CIRCUIT 6 300B 1
BOARD ASSY
7S611062 SWITCH MODULE 6 160B 1
BOARD ASSY
7S611113 TOP PLATE 2 130E 1
7S611444 MODIFICATION KIT 15 NA 1
NEW LOCK ASSEMBLY
(SB DA24-25-15)

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1019

MAINTENANCE MANUAL
DA 24 Series Coffee Makers

IPL, Figure 1

April 1, 1996
MAINTENANCE MANUAL
9. Detailed Parts List
FIG. 1 PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

ITEM PART NO. CODE /ASSY
1 72012400 COFFEE MAKER DA 24 A

Ser No. 0001 to 0199
1 72012400 COFFEE MAKER DA 24 B
Ser No. 0200 and up
1 72012410 COFFEE MAKER DA 24 C
1 72012420 COFFEE MAKER DA 24 D
2 MECHANICAL INSTALLATION
For details, see Figure 2
3 PILLOW PACK HOLDER
AND COFFEE SERVER
4 LOCKING ASSEMBLY
For details, see Figures 4A & B
5 WATER SYSTEM
6 ELECTRICAL SYSTEM
7 PRINTED CIRCUIT BOARD
ASSEMBLY
8 CONTROL PANEL ASSEMBLY
9 PRINTED CIRCUIT BOARD-
CONTROL PANEL
10 MOUNTING RAIL ASSEMBLY
11 SWITCH MODULE ASSEMBLY
12 SOLENOID VALVE ASSEMBLY
25-31-24 IPL Page 1021

MAINTENANCE MANUAL
Mechanical Installation
IPL, Figure 2

April 1, 1996
MAINTENANCE MANUAL
PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

FIG. 2 PART NO. CODE /ASSY
ITEM
MECHANICAL
INSTALLATION
100 BREW COMPARTMENT RF
100A 7S609640 . BREW COMPARTMENT A 1
Pre SB 24-25-1
100B 7S610122 . BREW COMPARTMENT A 1
Post SB 24-25-1
--100C 7S610999 . BREW COMPARTMENT B,C,D 1
--10 7S234683 . . ANCHOR-NUT 14
ATTACHING PARTS
--90 7S342538 . . BLIND-RIVET 28
*****
110 SIDE PANEL, LH RF
ATTACHING PARTS
--25 MS24693C49 . SCREW 10
(7S235550 H0212)
*****
110A 7S609681 . SIDE PANEL, LH A 1
Pre SB 24-25-1
110B 7S610127 . SIDE PANEL, LH A 1
Post SB 24-25-1
110C 7S610998 . SIDE PANEL, LH B,C,D 1
120 SIDE PANEL, RH RF
ATTACHING PARTS
--25 MS24693C49 . SCREW 5
(7S235550 H0212)
*****
120A 7S609680 . SIDE PANEL, RH A 1
Pre SB 24-25-1
120B 7S610126 . SIDE PANEL, RH A 1
Post SB 24-25-1
--120C 7S610997 . SIDE PANEL, RH B,C 1
--120D 7S611020 . SIDE PANEL, RH D 1
130 TOP PLATE RF
ATTACHING PARTS
--25 MS24693C49 . SCREW 5
(7S235550 H0212)
*****
25-31-24 IPL Page 1023

MAINTENANCE MANUAL

MECHANICAL
INSTALLATION
130A 7S609187 DELETED NP
130B 7S609665 . TOP PLATE A 1
Pre SB 24-25-1
130C 7S610123 . TOP PLATE A 1
Post SB 24-25-1
--130D 7S610995 . TOP PLATE B,C,D 1
--130E 7S611113 . TOP PLATE B,C,D 1
Post SB 24-25-12
Supersedes items 130A - D
140 7S609666 . . HANDLE 1
ATTACHING PARTS
150 7S236450 . . HINGE 2
--25 MS24693C49 . . SCREW 2
(7S235550 H0212)
*****
160 7S609624 . PRIMARY LOCK ASSY 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
*****
170 7S609638 . SECONDARY LOCK ASSEMBLY 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 1
(7S235550 H0212)
*****
--175 7S239063 . STICKER 1
SECONDARY LOCK
180 GUIDE BLOCK RF
ATTACHING PARTS
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
*****
180A 7S609629 . GUIDE BLOCK 1
Pre SB 24-25-1
180B 7S236629 . GUIDE BLOCK 1
Post SB 24-25-1

April 1, 1996
MAINTENANCE MANUAL

MECHANICAL
INSTALLATION
190 7S609170 . PIN 1
200 7S235884 . SPRING 1
210 7S609172 . BRACKET 1
ATTACHING PARTS
Pre SB DA24-25-1
--55 AN960C6L . WASHER 2
(7S235611 H0212)
--20 MS35338-136 . LOCK-WASHER 2
(7S235545 H0212)
--37 MS35649-244 . NUT 2
(7S235558 H0212)
*****
210 7S609172 . BRACKET 1
ATTACHING PARTS
Post SB DA24-25-1
--85 AN960C8 . . WASHER 2
(7S341080 H0212)
--22 MS35338-137 . . LOCK-WASHER 2
(7S235547 H0212)
--32 MS35649-284 . NUT 2
(7S235556 H0212)
*****
220 7S236480 . SLIDE STRIP, LH 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 3
(7S235550 H0212)
*****
230 7S236805 . SLIDE STRIP, RH 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 3
(7S235550 H0212)
*****
240 . LOCKING ASSY RF
240A 7S609646 . LOCKING ASSY A,B,C 1
Pre SB DF24-25-4
For details, see IPL Fig. 4A
240B 7S611007 . LOCKING ASSY A,B,C 1
Post SB DF24-25-4
For details, see IPL Fig. 4A
--240C 7S611039 . LOCKING ASSY D 1
For details, see IPL Fig. 4B
--ITEM NOT ILLUSTRATED
25-31-24 IPL Page 1025

MAINTENANCE MANUAL
Pillow Pack Holder & Coffee Server

IPL, Figure 3

April 1, 1996
MAINTENANCE MANUAL

PILLOW PACK HOLDER
ASSY& COFFEE SERVER
110 7S609670 . PILLOW-PACK 1
RAIL-ASSEMBLY
ATTACHING PARTS
7 7S234650 . WASHER 4
--20 MS35338-136 . LOCK-WASHER 4
(7S235545 H0212)
--27 MS51957-15 . SCREW 4
(7S235553 H0212)
*****
115 7S236507 . SET-SCREW 1
116 7S236508 . SET-SCREW 1
120 7S609329 . SEAL ASSEMBLY 1
130 . PILLOW PACK HOLDER ASSY RF
130A 7S609333 . PILLOW PACK HOLDER ASSY A,B,C 1
140 7S610948 . . PLATE A,B,C 1
145 . . HANDLE RF
145A 7S236443 . . HANDLE A,B,C 1
ATTACHING PARTS
--85 AN960C8 . . WASHER 2
(7S341080 H0212)
--22 MS35338-137 . . LOCK-WASHER 2
(7S235547 H0212)
60 7S235721 . . NUT 2
*****
--130B 7S609327 . PILLOW PACK HOLDER ASSY D 1
--130C 7S609331 . PILLOW PACK HOLDER ASSY 1
--145B 7S235365 . . HANDLE D 1
ATTACHING PARTS
--85 AN960C8 . . WASHER 2
(7S341080 H0212)
--83 7S237125 . . NUT 2
*****
25-31-24 IPL Page 1027

MAINTENANCE MANUAL

PILLOW PACK HOLDER
ASSY& COFFEE SERVER
150 7S609328 . . PILLOW PACK HOLDER 1
160 7S235911 . COFFEE SERVER 1
170 7S201777 . FIBER WASHER 1
180 7S235367 . NOZZLE 1
190 . BRACKET RF
ATTACHING PARTS
--22 MS35338-137 . LOCK-WASHER 2
(7S235547 H0212)
--32 MS35649-284 . NUT 2
(7S235556 H0212)
--65 7S236003 . WASHER 2
--85 AN960C8 . WASHER 2
(7S341080 H0212)
*****
190A 7S609626 . BRACKET A 1
Pre SB DA24-25-11
--190B 7S611049 . BRACKET A 1
Post SB DA24-25-11

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1029

MAINTENANCE MANUAL
Locking Assembly
IPL, Figure 4A
Effectivity: A, B, C

April 1, 1996
MAINTENANCE MANUAL
FIG. 4A PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

LOCKING ASSEMBLY A,B,C
7S609633 DELETED
120 7S236628 . HINGE 2
ATTACHING PARTS
--35 MS24693C47 . SCREW 2
(7S235557 H0212)
*****
130 7S239039 . SPRING, LH 1
Post SB 24-25-5
140 7S239040 . SPRING, RH 1
Post SB 24-25-5
150 LOCK PLATE RF
ATTACHING PARTS
--35 MS24693C47 . SCREW 2
(7S235557 H0212)
*****
150A 7S236671 . LOCK PLATE 1
Pre SB 24-25-4
150B 7S239043 . LOCK PLATE 1
Post SB 24-25-4
160 HANDLE RF
160A 7S609655 . HANDLE 1
Pre SB 24-25-1
160B 7S610130 . HANDLE 1
Post SB 24-25-1
ATTACHING PARTS
165 7S237141 . . GUIDE, HANDLE 1
Post SB 24-25-1
170 7S235918 . SPRING 1
180 7S235917 . LOCK-NUT 1
*****
--190 LOCKING ASSEMBLY RF
7S609646 . LOCKING ASSEMBLY RF
Pre SB DA24-25-4
7S611007 . LOCKING ASSEMBLY RF
Post SB DA24-25-4
For NHA, see Figure 2
25-31-24 IPL Page 1031

MAINTENANCE MANUAL

200 LOCKING ARM RF

200A 7S609645 . . LOCKING ARM 1
Pre SB DA24-25-4
200B 7S611008 . . LOCKING ARM 1
Post SB DA24-25-4
205 7S235652 . . SHRINKABLE TUBING 10 cm
(4 in)
210 7S610160 . . BRACKET 1
220 COVER NP
ATTACHING PARTS
--20 MS35338-136 . . LOCK-WASHER 2
(7S235545 H0212)
--5 MS51957-14 . . SCREW 2
(7S234530 H0212)
*****
220A 7S236440 . . COVER 1
Pre SB DA24-25-4
220B 7S237169 . . COVER 1
Post SB DA24-25-4
230 7S236483 . . SPRING, LH 1
ATTACHING PARTS
--20 MS35338-136 . . LOCK-WASHER 1
(7S235545 H0212)
--5 MS51957-14 . . SCREW 1
(7S234530 H0212)
*****
240 7S236484 . . SPRING, RH 1
ATTACHING PARTS
--20 MS35338-136 . . LOCK-WASHER 1
(7S235545 H0212)
--5 MS51957-14 . . SCREW 1
(7S234530 H0212)
*****
260 BRACKET, LH NP
ATTACHING PARTS
--7 7S234650 . WASHER 2
20 MS35338-136 . LOCK-WASHER 2
(7S235545 H0212)
--5 MS51957-14 . SCREW 2
(7S235530 H0212)
*****

April 1, 1996
MAINTENANCE MANUAL

260A 7S609687 . BRACKET, LH NP

(Pre SB DA24-25-4)
260B 7S610158 . BRACKET, LH NP
(Post SB DA24-25-4)
270 BRACKET, RH RF
ATTACHING PARTS
--7 7S234650 . WASHER 2
--20 MS35338-136 . LOCK-WASHER 2
(7S235545 H0212)
--5 MS51957-14 . SCREW 2
(7S235530 H0212)
*****
270A 7S609667 . BRACKET, RH NP
(Pre SB DA24-25-4)
270B 7S610157 . BRACKET, RH NP
(Post SB DA24-25-4)
280 7S236676 . SPRING NP
290 7S234906 . ELECTRICAL WIRE 25 cm
(10 in)
295 7S234493 . TERMINAL 2
ATTACHING PARTS
--7 7S234650 . WASHER 2
--20 MS35338-136 . LOCK-WASHER 2
(7S235545 H0212)
--5 MS51957-14 . SCREW 2
(7S234530 H0212)
*****
300 7S235853 . CONNECTOR 2
310 7S235854 . CONNECTOR-PIN 2
320 7S236472 . SENSOR-PIN HOLDER NP
330 7S236476 . SENSOR-PIN NP
340 7S236478 . HINGE-PIN NP
-- ITEM NOT ILLUSTRATED
25-31-24 IPL Page 1033

MAINTENANCE MANUAL
Locking Assembly
IPL, Figure 4B
Effectivity: D

April 1, 1996
MAINTENANCE MANUAL
FIG. 4B PART NUMBER AIRLINE NOMENCLATURE EFF. UNITS

--1 7S611039 LOCKING ASSEMBLY D RF

(For NHA see Fig. 2)
100 7S235915 . . HANDLE 1
ATTACHING PARTS
105 7S235917 . . LOCK NUT 1
*****
110 7S235918 . . SPRING 1
115 7S235962 . LOCKING BLOCK 1
ATTACHING PARTS
25 MS24693C-49 . SCREW 2
(7S235550 H0212)
*****
120 7S235495 . . INSULATOR 2
130 7S235505 . . COVER 1
140 7S235497 . INSULATOR 2
150 7S235496 . . ROD, CONDUCTOR 2
160 7S235649 . . INSULATION HOSE 6 cm
(2.5 in)
170 7S235498 . . LEVEL SENSOR 1
180 7S235499 . . LEVEL SENSOR 1
92 7S371003 . . NUT 4
20 MS35338-136 . . LOCK WASHER 4
(7S235545 H0212)
7 7S234650 . . WASHER 6
190 7S235652 . . SHRINKABLE TUBING 20 cm
(7.9 in)
200 7S236628 . HINGE 2
ATTACHING PARTS
25 MS24693C-49 . SCREW 2
(7S235550 H0212)
*****
210 7S239040 . SPRING 1
25-31-24 IPL Page 1035

MAINTENANCE MANUAL
Water System
IPL, Figure 5A (Sheet 1 of 2)
Effectivity: A

April 1, 1996
MAINTENANCE MANUAL

WATER SYSTEM
72012400 COFFEE MAKER A RF
Serial No. 0001 to 0199
72012400 COFFEE MAKER B RF
Serial No. 0200 and up
72012410 COFFEE MAKER C RF
72012420 COFFEE MAKER D RF
110 7S609660 . BOILER ASSY 1
120 7S236481 . 3-WAY TAP A 1
ATTACHING PARTS
--82 7S236666 . NUT A 2
*****
130 7S609679 . SHAFT ASSY A 1
ATTACHING PARTS
135 7S236508 . SET-SCREW A 1
*****
140 7S236665 . SPACER A 1
150 7S236664 . KNOB A 1
ATTACHING PARTS
155 7S236453 . SET-SCREW A 1
*****
160A 7S610005 CONTROL PANEL A RF
Pre SB DA24-25-11
160B 7S611047 CONTROL PANEL A RF
Post SB DA24-25-11
190 7S609688 . DRAIN PLUG 1
200 7S235120 . PRESSURE RELIEF 1
VALVE
210 7S235921 . GROMMET 1
220 WATER TAP BRACKET RF
220A 7S236672 WATER TAP BRACKET A,B,C 1
Superseded by item 220B
220B 7S237152 . WATER TAP BRACKET A,B,C 1
Supersedes item 220A
ATTACHING PARTS
225 7S609632 . SCREW 2
*****
25-31-24 IPL Page 1037

MAINTENANCE MANUAL
Water System
IPL, Figure 5A (Sheet 2 of 2)

April 1, 1996
MAINTENANCE MANUAL

WATER SYSTEM
230 7S609682 . WATER TAP A,B,C 1
235 7S235489 . . O-RING A,B,C 1
240 7S609686 . PIPE A,B,C 1
ATTACHING PARTS
250 7S609684 . CLAMP A,B,C 1
--25 MS24693C49 . SCREW 1
(7S235550 H0212)
*****
270 7S235659 . HOSE RF
Teflon, 0,6 x 0,4
270A . HOSE A 10 cm
ATTACHING PARTS (4 in)
B,C,D 13 cm
(5,12 in)
280 7S236667 . INSERT 2
281 7S235722 . SLEEVE 2
282 7S235723 . NUT 2
*****
270B . HOSE A 16 cm
ATTACHING PARTS (6,3 in)
B,C,D 27 cm
(10,6 in)
275 7S235930 . CLAMP 1
280 7S236667 . INSERT 1
281 7S235722 . SLEEVE 1
282 7S235723 . NUT 1
*****
270C . HOSE A 49 cm
Pre SB DA24-25-11 (19,3 in)
ATTACHING PARTS B,C,D 39 cm
(15,4 in)
275 7S235930 . CLAMP 1
280 7S236667 . INSERT 1
281 7S235722 . SLEEVE 1
282 7S235723 . NUT 1
*****
--270C 7S611048 . HOSE ASSEMBLY A 1
Post SB DA24-25-11
25-31-24 IPL Page 1039

MAINTENANCE MANUAL

WATER SYSTEM
270D . HOSE 16 cm
275 7S235930 . CLAMP 1
270E . HOSE A 20 cm
B,C,D 25 cm
(9,8 in)
280 7S236667 . INSERT 2
281 7S235722 . SLEEVE 2
282 7S235723 . NUT 2
*****
270F . HOSE 33 cm
275 7S235930 . CLAMP 1
280 7S236667 . INSERT 1
281 7S235722 . SLEEVE 1
282 7S235723 . NUT 1
*****
285 7S235725 . CAP B,C,D 1
290 7S611038 . WATERTAP ASSY D 1
ATTACHING PARTS
225 7S609632 . SCREW D 2
*****
295 7S234803 . AERATOR D 1

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1041

MAINTENANCE MANUAL
Water System
IPL, Figure 5B (Sheet 1 of 2)
Effectivity: A

April 1, 1996
MAINTENANCE MANUAL

WATER SYSTEM
270 7S235659 HOSE RF
Teflon, 0,6 x 0,4
270A HOSE RF
270B HOSE RF
270C HOSE RF
270F HOSE RF
270G . HOSE 9,5 cm
275 7S235930 . CLAMP 1
280 7S236667 . INSERT 1
281 7S235722 . SLEEVE 1
282 7S235723 . NUT 1
*****
290 SOLENOID VALVE RF
ATTACHING PARTS
--22 MS35338-137 . . LOCK-WASHER A 2
(7S235547 H0212) B,C,D 4
--85 AN960C8 . . WASHER A 2
(7S341080 H0212) B,C,D 4
--30 MS51957-43 . SCREW A 2
(7S235555 H0212) B,C,D 4
*****
290A 7S235020 . SOLENOID VALVE NP
290B 7S239107 . SOLENOID VALVE 3
Post SB DA24-25-13
295 7S235995 . RESTRICTOR 1
300 7S235664 . UNION 1
305 7S609344 . T-FITTING 2
310 7S235666 . ELBOW FITTING 1
25-31-24 IPL Page 1043

MAINTENANCE MANUAL
Water System
IPL, Figure 5B (Sheet 2 of 2)

April 1, 1996
MAINTENANCE MANUAL

WATER SYSTEM
320A 7S609802 . VENT VALVE ASSY NP
Pre SB DA24-25-10
7S236340 . . HOUSING NP
7S235804 . . HOSE NIPPLE (soldered) NP
7S235803 . . NUT NP
7S237240 . . SEAL NP
7S236246 . . BALL NP
7S236341 . . SPACER NP
7S236804 . . PIN NP
320B 7S610923 . VENT VALVE ASSY 1
Post SB DA24-25-10
330 7S201945 . O-RING 1
340 7S609289 . TEMPERATURE 1
SENSOR
7S609412 DELETED
350 7S610958 . LEVEL SENSOR ASSY 1
360 7S609660 BOILER ASSY RF
ATTACHING PARTS
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
*****
365 7S236098 . INSULATION 1
7S236099 DELETED
370 . REAR PANEL ASSY RF
ATTACHING PARTS
7S609628 BRACKET DELETED
--85 AN960C8 . WASHER 2
(7S341080 H0212)
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
--22 MS35338-137 . LOCK-WASHER 2
(7S235547 H0212)
--30 MS51957-43 . SCREW 2
(7S235555 H0212)
*****
25-31-24 IPL Page 1045

MAINTENANCE MANUAL

WATER SYSTEM
370A 7S609676 . REAR PANEL ASSY A 1
--63 7S235979 . . RIVNUT A 3
--10 7S234683 . . ANCHOR NUT A 2
ATTACHING PARTS
--88 7S342536 . . BLIND RIVET A 4
*****
370B 7S610990 . REAR PANEL ASSY B,C,D 1
--63 7S235979 . . RIVNUT B,C,D 2
--64 7S235980 . . RIVNUT B,C,D 2
--10 7S234683 . . ANCHOR NUT B,C,D 2
ATTACHING PARTS
--88 7S342536 . . BLIND RIVET B,C,D 4
*****
375 7S610989 . BRACKET B,C,D 1
ATTACHING PARTS
--85 AN960C8 . WASHER 2
(7S341080 H0212)
--22 MS35338-137 . LOCK-WASHER 2
(7S235547 H0212)
--30 MS51957-43 . SCREW 2
(7S235555 H0212)
*****
380 7S609677 . FRAME, CONNECTOR 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
*****

April 1, 1996
MAINTENANCE MANUAL

WATER SYSTEM
400 7S609005 . WATER COUPLING 1
ASSEMBLY
ATTACHING PARTS
410 7S609995 . NUT PLATE 1
Superseded by item 37
--7 7S234650 . WASHER 4
--20 MS35338-136 . LOCK-WASHER 4
(7S235545 H0212)
--37 MS35649-244 . NUT 4
Supersedes item 410
(7S235558 H0212)
--42 MS51957-17 . SCREW 4
(7S235565 H0212)
*****
420 7S236728 . . O-RING 1
425 7S234019 . . O-RING 1
430 7S609625 . DRAIN 1
ATTACHING PARTS
(7S235611 H0212)
--20 MS35338-136 . LOCK-WASHER 2
(7S235545 H0212)
--37 MS35649-244 . NUT 2
(7S235558 H0212)
--5 MS51957-14 . SCREW 2
(7S234530 H0212)
*****
440 7S236062 . DRAIN PIPE 1
450 7S609661 . HEATING ELEMENT 3
460 7S235062 . O-RING 3
470 7S609690 . MANIFOLD 1
25-31-24 IPL Page 1047

MAINTENANCE MANUAL
Electrical System
IPL, Figure 6 (Sheet 1 of 2)
Effectivity: A

April 1, 1996
MAINTENANCE MANUAL

ELECTRICAL SYSTEM
130 BOILER ASSY RF
140 REAR PANEL ASSY RF
150 FRAME, CONNECTOR RF
160 CONTROL PANEL/ RF
SWITCH MODULE ASSY
ATTACHING PARTS
--35 MS24693C47 . SCREW 2
(7S235557 H0212)
*****
160A 7S610005 . CONTROL PANEL A NP
Pre SB DA24-25-11
160A 7S611047 . CONTROL PANEL A 1
Post SB DA24-25-11
160B 7S610994 . SWITCH MODULE ASSEMBLY B,C,D NP
Pre SB DA24-25-75
160B 7S611062 . SWITCH MODULE ASSEMBLY B,C,D 1
Post SB DA24-25-8
170 7S609112 . OPTO-COUPLER 1
ATTACHING PARTS
--2 7S201235 . WASHER 2
--42 MS51957-17 . SCREW 2
(7S235565 H0212)
*****
25-31-24 IPL Page 1049

MAINTENANCE MANUAL

ELECTRICAL SYSTEM
190 7S236560 . SPRING-SET 1
200 7S234848 . GROMMET 2
210 7S609636 . GROUND WIRE 2
210A GROUND WIRE RF
ATTACHING PARTS
--45 NAS1096-1-6 . BOLT 1
(7S235603 H0212)
(7S235611 H0212)
--52 MS35649-262 . NUT 1
(7S235610 H0212)
--15 7S235284 CABLE TIE 1
--85 AN960C8 . WASHER 1
(7S341080 H0212)
--22 MS35338-137 . LOCK-WASHER 1
(7S235547 H0212)
--50 NAS679S08 . NUT 1
(7S235608 H0212)
*****
210B GROUND WIRE RF
ATTACHING PARTS
--47 NAS1096-1-8 . BOLT 1
(7S235604 H0212)
(7S235611 H0212)
--57 AN9356L . LOCK-WASHER 2
(7S235612 H0212)
--52 MS35649-262 . NUT 2
(7S235610 H0212)
*****
--85 AN960C8 . WASHER 1
(7S341080 H0212)
--22 MS35338-137 . LOCK-WASHER 1
(7S235547 H0212)
--50 NAS679S08 . NUT 1
(7S235608 H0212)
*****

April 1, 1996
MAINTENANCE MANUAL

ELECTRICAL SYSTEM
220 7S609409 . HEAT-CONDUCTING PLATE A 1
230 7S235082 . THERMOSTAT A 1
ATTACHING PARTS
--7 7S234650 . WASHER A 2
--20 MS35338-136 . LOCK-WASHER A 2
(7S235545 H0212)
--37 MS35649-244 . NUT A 2
(7S235558 H0212)
*****
--15 7S235284 . CABLE TIE 2
ATTACHING PARTS
--85 AN960C8 . WASHER 2
(7S341080 H0212)
--22 MS35338-137 . LOCK-WASHER 2
(7S235547 H0212)
--50 NAS679S08 . NUT 2
(7S235608 H0212)
*****
240 7S236442 . HEATING ELEMENT 1
250 INSULATION RF
250A 7S236099 . INSULATION 1
Pre SB 24-25-1
250B 7S237018 . INSULATION 1
Post SB 24-25-1
260 COVER RF
260A 7S609627 . COVER 1
Pre SB 24-25-1
ATTACHING PARTS
(7S235611 H0212)
--20 MS35338-136 . LOCK-WASHER 3
(7S235545 H0212)
--37 MS35649-244 . NUT 3
(7S235558 H0212)
*****
25-31-24 IPL Page 1051

MAINTENANCE MANUAL
Electrical System
IPL, Figure 6 (Sheet 2 of 2)

April 1, 1996
MAINTENANCE MANUAL

ELECTRICAL SYSTEM
260B 7S609664 . COVER 1
Post SB 24-25-1
ATTACHING PARTS
--85 AN960C8 . . WASHER 3
(7S341080 H0212)
--22 MS35338-137 . . LOCK-WASHER 3
(7S235547 H0212)
--32 MS35649-284 . . NUT 3
(7S235556 H0212)
*****
270 7S609675 . FRAME, PCB 1
ATTACHING PARTS
--25 MS24693C49 . SCREW 2
(7S235550 H0212)
*****
10 7S234683 . . ANCHOR NUT 5
ATTACHING PARTS
--88 7S342536 . . BLIND RIVET 10
*****
280 7S609983 . INSULATION PLATE 1
290 7S235795 . PCB HOLDER 2
300 . PRINTED CIRCUIT RF
BOARD ASSY
ATTACHING PARTS
(7S235611 H0212)
--57 AN9356L . . LOCK-WASHER 2
(7S235612 H0212)
--47 NAS1096-1-8, . BOLT 1
(7S235604 H0212)
*****
300A 7S609285 . PRINTED CIRCUIT NP 1
BOARD ASSY
Pre SB DA24-25-9
For details, see Fig. 6
300B 7S611058 . PRINTED CIRCUIT 1 1
BOARD ASSY
Post SB DA24-25-9
--305 7S235694 . CABLE 1
310 7S235904 . CAPACITOR 4
320 7S235122 . GROMMET 1
330 7S235041 . RELAY 1
25-31-24 IPL Page 1053

MAINTENANCE MANUAL

ELECTRICAL SYSTEM
340 TERMINAL STRIP RF
ATTACHING PARTS
--20 MS35338-136 . LOCK-WASHER 2
(7S235545<T>H0212)
--5 MS51957-14 . SCREW 2
(7S234530<T>H0212)
*****
340A 7S236705 . TERMINAL STRIP A 1
340B 7S236706 . TERMINAL STRIP B,C,D 1
--345 7S608059 . STRIP 1
350 COVER RF
350A 7S236715 . COVER A 1
350B 7S236716 . COVER B,C,D 1
360 WIRING HARNESS RF
ATTACHING PARTS
--15 7S235284 . . CABLE TIE 2
--57 AN935-6L . . LOCK-WASHER 2
(7S235612 H0212)
--85 AN960C8 . . WASHER 2
(7S341080 H0212)
--32 MS35649-284 . . NUT 2
(7S235556 H0212)
*****
360A 7S609229 . WIRING HARNESS A 1
360B 7S611000 . WIRING HARNESS B,C,D 1
--365 7S220122 . . SPIRAP 45 cm
(18 in)
--366A 7S234906 . . ELECTRICAL WIRE A 990 cm
AWG 20, (390 in)
--366B 7S239072 . . ELECTRICAL WIRE B,C,D 990 cm
AWG 22 (390 in)
--367 7S234907 . . ELECTRICAL WIRE 50 cm
AWG 16 (20 in)
--368 7S234908 . . ELECTRICAL WIRE 420 cm
AWG 18 (166 in)
--12 7S235283 . . CABLE TIE 32

April 1, 1996
MAINTENANCE MANUAL

ELECTRICAL SYSTEM
370 7S235075 . . 3-PHASE 1
SAFETY-DEVICE
ATTACHING PARTS
--85 AN960C8 . . WASHER 2
(7S341080 H0212)
--22 MS35338-137 . . LOCK-WASHER 2
(7S235547 H0212)
--32 MS35649-284 . . NUT 2
(7S235556 H0212)
*****
380 7S236491 . . RECEPTACLE 1
--385 7S236492 . . SOCKET 15
390 7S609572 . . CONNECTOR 1
--395 7S235848 . . CRIMP-SNAP 5
400 7S235851 . . CONNECTOR HOUSING 4
405 7S235852 . . CONNECTOR PIN 4
--55 AN960C6L . . WASHER 2
(7S235611 H0212)
--20 MS35338-136 . . LOCK-WASHER 2
(7S235545 H0212)
--37 MS35649-244 . . NUT 2
(7S235558 H0212)
--42 MS51957-17 . . SCREW 2
(7S235565 H0212)
*****
410 7S236470 . . CONNECTOR 1
ATTACHING PARTS
--55 AN960C6L . . WASHER 2
(7S235611 H0212)
--20 MS35338-136 . . LOCK-WASHER 2
(7S235545 H0212)
--37 MS35649-244 . . NUT 2
(7S235558 H0212)
--17 MS51657-18 . . SCREW 2
(7S235358 H0212)
*****
25-31-24 IPL Page 1055

MAINTENANCE MANUAL

ELECTRICAL SYSTEM
--415 7S236458 . . KEYING PLUG 1
--420 7S236459 . . CONTACT 25
430 7S238307 . . DIODE 2
--435 7S348385 . . CONNECTOR, PARALLEL 4
440 7S235044 . . RELAY SOCKET ASSY 1
450 GROUND WIRE RF
ATTACHING PARTS
--47 NAS1096-1-8 . BOLT 1
(7S235604 H0212)
--57 AN935-6L . LOCK-WASHER 1
(7S235612 H0212)
(7S235611 H0212)
--52 MS35649-262 . NUT 1
(7S235610 H0212)
--51 NAS679A06W . NUT 1
(7S235609 H0212)
*****
460 CONNECTOR RF
460A 7S235709 . . CONNECTOR 1
(Pre SB DA24-25-6)
460B 7S239061 . . CONNECTOR 1
(Post SB DA24-25-6)
ATTACHING PARTS
470 7S236669 . SPACER 1
Superseded by item 470A
--470A 7S239119 . SPACER 1
Supersedes item 470
480 7S609634 . LOCKPLATE 1
490 7S609982 . NUT PLATE 1
--7 7S234650 . WASHER 4
--20 MS35338-136 . LOCK-WASHER 4
(7S235545 H0212)
37 MS35649-244 . NUT 4
(7S235558 H0212)
Supersedes item 490
--42 MS51957-17 . SCREW 4
(7S235565 H0212)
*****

April 1, 1996
MAINTENANCE MANUAL

ELECTRICAL SYSTEM
7S609630 DELETED
500 7S234492 . . TERMINAL 10
510 7S234496 . . TERMINAL 6
520 7S235051 . . RELAY SOCKET ASSY B,C,D 1
530 7S235047 . . RELAY B,C,D 1
25-31-24 IPL Page 1057

MAINTENANCE MANUAL
Printed Circuit Board Assy

IPL, Figure 7A

April 1, 1996
MAINTENANCE MANUAL

7S609285 PRINTED CIRCUIT RF

BOARD ASSY
For NHA see IPL Fig. 6
100 7S236240 PRINTED CIRCUIT BOARD 1
110 7S235991 . TRANSFORMER 1
ATTACHING PARTS
--20 MS35338-136 . LOCK-WASHER 1
(7S235545 H0212)
--2 7S201235 . WASHER 1
--70 7S236242 . SCREW 1
--92 7S371003 . NUT 1
*****
120 7S238301 . DIODE 10
IN4004
130 7S238318 . DIODE 1
1N5650A
140 7S238319 . VOLT. REG. DIODE 1
BZV85C12, 12 V, 1,3 W
150 7S238057 . TRANSISTOR 5
2N3700
160 7S238320 . VOLT. REG. DIODE 1
12 V - 0,5 W, BZX79C12
170 7S238302 . DIODE 7
3 V, 1N4148
180 7S238114 . INTEGRATED CIRCUIT 3
MC1741U
MC14049U BAL
MC14011BAL
MC14013BAL
MC14584BAL
MC14023BAL
240 7S238316 . DIODE 2
12 V, 3,25 W, 1N3595DHD
25-31-24 IPL Page 1059

MAINTENANCE MANUAL

250 7S238058 . TRANSISTOR 1

TIP 120 T0220
ATTACHING PARTS
--20 MS35338-136 . LOCK-WASHER 1
(7S235545 H0212)
--2 7S201235 . WASHER 1
--92 7S371003 . NUT 1
--95 7S371105 . SCREW 1
*****

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1061

MAINTENANCE MANUAL
Printed Circuit Board Assy

IPL, Figure 7B

April 1, 1996
MAINTENANCE MANUAL

260 7S238610 . RESISTOR, 10K Ω 6

0,6 W
270 7S238666 . RESISTOR, 15K8Ω 5
± 1%, 0,6 W
280 7S238517 . CAPACITOR 13
10 nF, 200 V
290 7S238583 . CAPACITOR 1
1 µ F, 63 V
300 7S238523 . CAPACITOR (glued) 1
470 µ F, 66 V
310 7S238660 . RESISTOR, 390 Ω, ± 5 % 1
3W
320 7S238683 . RESISTOR, 5,6 Ω 1
± 1%, 5 W
330 7S238625 . RESISTOR, 1K Ω 1
± 1%, 0,6 W
340 7S238671 . RESISTOR, 28K Ω 2
± 1%, 0,6 W
350 7S238628 . RESISTOR, 100K Ω 3
0,6 W
360 7S238668 . RESISTOR, 392K Ω 1
± 1%, 0,6 W
370 7S238680 . RESISTOR, 274 Ω ± 1 % 2
0,6 W
380 7S238673 . RESISTOR, 221 Ω 1
0,6 W
390 7S238681 . RESISTOR, 27K4 Ω 1
0,6 W
400 7S238667 . RESISTOR, 6K49 Ω, 4
± 1%, 0,6 W
410 7S238664 . POTENTIOMETER 2
2K Ω, ± 10% 0,5 W
420 7S238662 . POTENTIOMETER 1
100 Ω, ± 10% 0,5 W
430 7S238614 . RESISTOR, 2K21 Ω, 3
± 5 %, 0,6 W
440 7S238615 . RESISTOR, 221K Ω 1
± 1%, 0,6 W
450 7S238620 . RESISTOR, 1M Ω 4
± 1%, 0,6 W
25-31-24 IPL Page 1063

MAINTENANCE MANUAL

460 7S238531 . CAPACITOR 1

2,2 µ F, 100 V
470 7S238526 . CAPACITOR 3
470 nF, 100 V
480 7S238682 . RESISTOR, 10M Ω 1
± 5%, 0,5 W
490 7S238678 . RESISTOR, 2M2 Ω 1
± 5%, 0,33 W
500 7S238674 . RESISTOR, 39K2 Ω 1
± 1%, 0,6 W
510 7S238520 . CAPACITOR 1
220 nF, 50 V
520 7S234912 . CAPACITOR 1
22 nF, 100V

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1065

MAINTENANCE MANUAL
Control Panel Assembly - 7S610005

IPL, Figure 8
Effectivity: A

April 1, 1996
MAINTENANCE MANUAL

7S61005 CONTROL PANEL A RF

ASSEMBLY
For NHA, see IPL Fig. 6
100 7S609694 . FRONT PANEL 1
105 7S609641 . BRACKET 2
110 7S609649 . PRINTED CIRCUIT BOARD 1
For details, see IPL Fig. 9
ATTACHING PARTS
115 7S201235 . WASHER 6
120 7S236655 . SPACER 4
125 7S236657 . SPACER 4
--62 NAS679C04W . NUT 6
(7S235770<T>H0212)
*****
135 7S236448 . CONNECTOR 1
--136 7S236444 . PIN 15
--140 7S236228 . CLAMP ASSEMBLY 2
25-31-24 IPL Page 1067

MAINTENANCE MANUAL
Printed Circuit Board - Control Panel

IPL, Figure 9

April 1, 1996
MAINTENANCE MANUAL

7S609649 PRINTED CIRCUIT A RF

BOARD- CONTROL PANEL
100 7S236649 . BOARD 1
105 7S236648 . SPACER 10
110 7S238686 . RESISTOR, TK50 2
MK2-105E
115 7S238700 . RESISTOR, TK50 1
MK2-56K2
120 7S238685 . RESISTOR, TK50 2
MK2-33K2
125 7S238701 . RESISTOR, TK200 4
WK4-10K
130 7S238780 . RESISTOR, 33E 20 % 1
K164-K4033M
135 7S238533 . CAPACITOR, KER, 2E 3
CK06BX105K
140 7S238534 . CAPACITOR, KER, 2E 4
CK06BX474K
145 7S238307 . DIODE, 1N4007 12
150 7S238321 . LED, YELLOW 2
TLHY4205
155 7S238322 . LED, RED 2
TLHR4405
160 7S238330 . LED, GREEN 2
TLHG4205
165 7S238309 . VOLT. REG. DIODE, BZT03C27 2
170 7S238331 . VOLT. REG. DIODE, 1
BZX83C15V
175 7S238100 . FET OPTO-COUPLER 2
HSSR8200
180 7S238060 . MOS NFET 1
ZVN2110A
185 7S238399 . 7 SEGM. DISPLAY 2
HDSP7401
190 7S236924 . RELAY, 2
V23042-B2203-B101
25-31-24 IPL Page 1069

MAINTENANCE MANUAL

195 7S236167 . SWITCH, SKHCAC 3

200 7S238702 . SILRES, 4RES 39K 1
4608X-102-393
205 7S238703 . SILRES, 3 RES 6K8 4
4606X-102-682

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1071

MAINTENANCE MANUAL
Mounting Rail Assembly (Optional)

IPL, Figure 10

April 1, 1996
MAINTENANCE MANUAL

7S609609 MOUNTING RAIL ASSY X 1

7S609642 MOUNTING RAIL ASSY Y 1
7S609669 MOUNTING RAIL ASSY Z 1
100 7S609635 . MOUNTING RACK NP
110 . WATER COUPLING RF
110A 7S609980 . WATER COUPLING X,Y 1
ASSEMBLY
Superseded by item 110C
ATTACHING PARTS
110B 7S609985 . WATER COUPLING ASSEMBLY Z 1
ATTACHING PARTS
110C 7S610139 . WATER COUPLING X,Y 1
ASSEMBLY
Supersedes item 110A
ATTACHING PARTS
17 MS51657-18 . SCREW 4
(7S235358 H0212)
62 NAS679C04W . NUT 4
(7S235770 H0212)
7 7S234650 . WASHER 8
*****
120 7S234907 . ELECTRICAL WIRE 200 cm
(79 in)
80 MS20500-1032 . NUT 1
(7S236572 H0212)
67 7S236116 . WASHER 4
77 7S236462 . SCREW 1
--71 MS51957-46 . SCREW 1
(7S236431 H0212)
Supersedes item 77
--85 7S341080 . WASHER 3
Supersedes item 67
--22 MS35338-137 . LOCK-WASHER 1
*****
25-31-24 IPL Page 1073

MAINTENANCE MANUAL

130 7S236436 . NIPPLE 1

140 . DRAIN NIPPLE RF
140A 7S236654 . DRAIN NIPPLE X 1
140B 7S237136 . DRAIN NIPPLE Y,Z
150 7S236435 . NIPPLE X 1
160 7S236658 . O-RING 1
170 7S236455 . CONNECTOR 1
ATTACHING PARTS
17 MS51657-18 . SCREW 4
(7S235358 H0212)
62 NAS679C04W . NUT 4
(7S235770 H0212)
7 7S234650 . WASHER 8
*****
180 7S235485 . O-RING 1
190 7S236434 . PIN 1
ATTACHING PARTS
72 7S236432 . NUT 1
75 7S236433 . WASHER 1
87 7S341252 . LOCK-WASHER 1
*****

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1075

MAINTENANCE MANUAL
Switch Module Assembly - 7S610994

IPL, Figure 11

April 1, 1996
MAINTENANCE MANUAL

--1 7S610994 . SWITCH MODULE ASSY B,C,D RF

Pre SB DA24-25-8
7S611062 . SWITCH MODULE ASSY B,C,D RF
Post SB DA24-25-8
7S239075 DELETED
100 7S611104 . . PRINTED CIRCUIT BOARD 1
ASSY
Post SB DA24-25-8
ATTACHING PARTS
2 7S201235 . . WASHER 2
20 MS35338-136 . . LOCK-WASHER 2
(7S235545 H0212)
37 MS35649-244 . . NUT 2
(7S235558 H0212)
*****
105 7S239074 . . STUD 2
110 7S239076 . . FRONT PLATE 1
115A 7S237250 . . LENS, ON/OFF 1
115B 7S237255 . . LENS, NO WATER ? 1
OUT OF ORDER
115C 7S237251 . . LENS, WATER IS HOT 1
115D 7S237252 . . LENS, HOT WATER 1
115E 7S237253 . . LENS, COLD WATER 1
115F 7S237254 . . LENS, BREW 1
115G 7S237256 . . LENS, BREW READY 1
120 7S237245 . . FRAME 7
125 7S237247 . . LOCK-RING 7
130A 7S237235 . . ELEMENT 1
130B 7S237236 . . ELEMENT 3
135A 7S237242 . . SWITCH ELEMENT 1
135B 7S237243 . . SWITCH ELEMENT 3
140 7S237233 . . CONNECTOR 4
25-31-24 IPL Page 1077

MAINTENANCE MANUAL

145 7S236560 . . SPRING-SET 1

150 7S237260 . . CONNECTOR 1
2 7S201235 . . WASHER 4
17 MS51657-18 . . SCREW 2
(7S235358 H0212)
62 NAS679C04W . . NUT 2
(7S235770 H0212)
155 7S236657 . . SPACER 2
--160 7S237259 . . LED, YELLOW 5
(DELETED) (Pre SB DA24-25-14)
-- 160A 7S239581 .. LED (RED) 1
(Post SB DA24-25-14)
-- 160B 7S239582 .. LED (YELLOW) 3
-- 160C 7S239583 .. LED (GREEN) 1
165 7S237237 . . ELEMENT 3
170 7S237234 . . CONNECTOR 1
175 7S237265 . . COVER 4
180 7S239073 . . PLACARD 1

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1079

MAINTENANCE MANUAL
Solenoid Valve - 7S239107

IPL, Figure 12

April 1, 1996
MAINTENANCE MANUAL

7S235020 DELETED NP
100 7S239107 SOLENOID VALVE ASSY RF
For NHA see Fig. 5B
110 7S239189 . REPAIR KIT 1
120 . . O-RING 1
130 7S239414 . . PLUNGER 1
140 . . SPRING 1
25-31-24 IPL Page 1081

MAINTENANCE MANUAL
Level Sensor and Vent Valve Assemblies

Figure 13

April 1, 1996
MAINTENANCE MANUAL

100 7S610958 LEVEL SENSOR ASSY RF

(For NHA see IPL Fig. 5B)
110 7S235806 . LEVEL SENSOR 1
120 7S235722 . SLEEVE 1
130 7S235723 . NUT 1
140 7S235807 . INSULATION SLEEVE 1
8 DIN 125A . WASHER 1
7S234650 H0212
22 MS35649-244 . NUT 1
7S235558 H0212
200 7S610923 VENT VALVE ASSY RF

(For NHA see IPL Fig. 5B)
210 7S235803 . NUT 1
220 7S239013 . HOUSING 1
230 7S239009 . HOSE-NIPPLE 1
240 7S239015 . SEAL 1
250 7S239017 . SPACER 1
260 7S239016 . BALL 1
270 7S239010 . SPRING 1
25-31-24 IPL Page 1083

MAINTENANCE MANUAL
Switch Module Assembly - 7S611047

IPL, Figure 14

April 1, 1996
MAINTENANCE MANUAL

--1 7S611047 . SWITCH MODULE ASSEMBLY RF

For NHA, see Figure 5A
100 7S611050 . . PRINTED CIRCUIT 1
BOARD ASSY
ATTACHING PARTS
2 7S201235 . . WASHER 2
20 MS35338-136 . . LOCK-WASHER 2
7S235545 H0212
37 MS35649-244 . . NUT 2
7S235558 H0212
*****
105 7S239150 . . . BOARD 1
110 7S237233 . . . CONNECTOR 2
115 7S237234 . . . CONNECTOR 2
120 7S236448 . . . CONNECTOR 1
125 7S236228 . . . CLAMP - SET 1
130 7S239154 . . . CONTACT 2
135 7S239153 . . . CONTACT-HOUSING 2
140 7S238616 . . . RESISTOR 2
145 7S239194 . . . RESISTOR 1
150 7S239171 . . . ZENER DIODE 1
155 7S239072 . . . WIRE 140 cm
(55 in)
160 7S234790 . . . SPIRAL WRAP 12 cm
(4.7 in)
165 7S239158 . . STUD 2
170 7S239151 . . FRONT PLATE 1
175 7S237250 . . LENS, ON/OFF 1
180 7S237255 . . LENS, NO WATER 1
185 7S237254 . . LENS, BREW 1
190 7S237256 . . LENS, BREW READY 1
195 7S237251 . . LENS, WATER IS HOT 1
25-31-24 IPL Page 1085

MAINTENANCE MANUAL

200 7S237259 . . LED 5

DELETED (Pre SB DA24-25-14)
200A 7S239581 .. LED RED 1
200B 7S239582 .. LED YELLOW 3
200C 7S239583 .. LED GREEN 1
205 7S237245 . . FRAME 5
210 7S237247 . . LOCK-RING 5
215 7S237235 . . ELEMENT 1
220 7S237236 . . ELEMENT 1
225 7S237265 . . COVER 2
230 7S239132 . . SWITCH ELEMENT 1
235 7S237243 . . SWITCH ELEMENT 1
240 7S237237 . . ELEMENT 3
245 7S239152 . . PLACARD 1
12 7S235283 . . CABLE TIE 3

April 1, 1996
MAINTENANCE MANUAL
INTENTIONALLY
LEFT BLANK
25-31-24 IPL Page 1087

MAINTENANCE MANUAL
Figure 15
Modification Kit New Lock Assembly 7S611444
For detail refer to SB24-25-15

April 1, 1996
MAINTENANCE MANUAL

7S611444 MODIFICATION KIT
NEW LOCK ASSEMBLY
(SB24-25-15)
25-31-24 IPL Page 1089


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COMPONENT

72012400, 72012410, 72012420

25-31-24 Title Page 1

Title Page 2 25-31-24

Rev.No Issue Date Date Inserted By

1 July 01, 1993

25-31-24 R.O.R . Page 1

R.O.R. Page 2 25-31-24

RECORD OF TEMPORARY REVISIONS

Temp Issue Inserted Date Removed Date

25-31-24 R.O.T.R. Page 1

R.O.T.R. Page 2 25-31-24

SERVICE BULLETIN LIST

S.B. NUMBER ISSUE DATE SUBJECT INCORPORATED

25-31-24 S.B. List Page 1

S.B. List Page 2 25-31-24

LIST OF EFFECTIVE PAGES

This manual has the following pages:

Title Page July 1, 1997

Page Date Page Date Page Date

1 April 1, 1996 111 April 1, 1996 501 April 1, 1996

25-31-24 L.E.P. Page 1

Page Date Page Date Page Date

1001 April 1, 1996 1031 April 1, 1996 1061 April 1, 1996

L.E.P. Page 2 25-31-24

Description and Operation 1

DA 24 Coffee Makers - General 1

25-31-24 T.O.C. Page 1

Title Figure No.

Printed Circuit Board Assy IPL 7A

T.O.C. Page 2 25-31-24 Revision 2

This manual is prepared in accordance with:

MODEL PART No. SERIAL No. Eff:

DA 24 72012400 0001 to 0199 A

25-31-24 Intro. Page 1

3. General Maintenance Practices

- Remove the coffee server

(1) Weekly, make sure that:

-there is no evidence of internal leakage

Faults must be corrected.

Intro. Page 2 25-31-24

DESCRIPTION AND OPERATION

MODEL PART No. SERIAL No. Eff:

DA 24 72012400 0001 to 0199 A

The coffee makers have: -a coffee pillow pack

Effectivity: A Effectivity: B,C,D

-Height 304 mm (11.97 in)

Revision 2 25-31-24 D&O Page 1

DA 24 Coffee Makers - General

D&O Page 2 25-31-24 Revision 2

3. Operation [Effectivity: A (Pre SB DA24-25-11)]

The coffee maker operates when:

The CODE indicator shows 01 when the coffee maker is unserviceable.

-The ON/OFF light comes on.

25-31-24 D&O Page 3

-The BREW light comes on.

D. The coffee is ready to be served.

NOTE: If it becomes necessary to interrupt the brew cycle, i.e. to replace a

E. Hot and Cold Water Supply

D&O Page 4 25-31-24

4. Operation (Effectivity B,C,D)

The coffee maker operates when: