WATER SYSTEM ASSEMBLY

PART

NUMBER

HC-3801

Component Maintenance Manual With Illustrated Parts List

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RECORD OF REVISIONS REV. NO INSERTION DATE BY REV. NO INSERTION DATE BY

RETAIN THIS RECORD IN THE FRONT OF THE MANUAL OR CHAPTER. ON RECEIPT OF REVISIONS,INSERT REVISED PAGES IN THE MANUAL,AND ENTER REVISION NUMBER,DATE INSERTED,AND INITIAL.
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RECORD OF TEMPORARY REVISIONS TEMPORARY REVISION NO. PAGE NO. ISSUE DATE BY DATE REMOVED BY

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SERVICE BULLETIN LIST BULLETIN NO. REVISION NO. ISSUE DATE DATE INCORPORATED

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LIST OF EFFECTIVE PAGES CHAPTER/ SECTION Title Page PAGE DATE MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 CHAPTER/ SECTION Repair PAGE 601 602 701 702 703 704 705 706 707 708 709 710 711 712 801 802 901 Special Tools,Fixtures and Equipment 902 1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 DATE MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY 18/08 MAY MAY MAY MAY MAY MAY MAY MAY MAY MAY MAY MAY MAY MAY 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08 18/08

T-1 T-2 RR-1 Record of Revisions RR-2 Record of RTR-1 Temporary RTR-2 Revisions SBL-1 Service Bulletin List SBL-2 List of Effective LEP-1 Pages LEP-2 TOC-1 Table of Contents TOC-2 INTRO-1 Instroduction INTRO-2 Description and 1 Operation 2 101 102 103 Testing and Fault 104 Isolation 105 106 107 108 301 302 303 Disassembly 304 305 306 401 402 Cleaning 403 404 501 Check 502

Assembly

Fits and Clearances

Illustratated Parts List(IPL)

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TABLE OF CONTENTS NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FIG NO. INTRO FIG.1 SYSTEM EXPLAIN FIG.1 FIG.1001 FIG.1002 FIG.6001 FIG.6002 FIG. 9001 FIG. 9002 IPL FIG. 1 IPL FIG. 2 IPL FIG. 3 IPL FIG. 4 IPL FIG. 5 IPL FIG. 6 IPL FIG. 6 IPL FIG. 7 NAME PAGE NO.

WATER SYSTEM ASSEMBLY INTRO-2 FACADE HC-3801 WATER SYSTEM ASSEMBLY PANE SCHEMATICS TEST CONNECTION DIAGRAM TEST SET UP PRINCIPLE DIAGRAM 11OF2 PRINCIPLE DIAGRAM 2(2OF2 FAUCET SPECIAL TOOL WRENCH COPING FOR DRAIN VALVE

SYSTEM ASSEMBLY FAUCET ASSEMBLY DRAIN VALVE ASSEMBLY WATER HEATER ASSEMBLY ELECTRONICS BOX ASSEMBLY PCB1of2 PCB2of2 PUMP ASSEMBLY

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INTRODUCTION 1 Relating 1.1 Drawing up this manual is according to XIAN AIRCROFT INDUSTRY GROUP COMPANY LTD provision to maintain a manual the local airplane carry an equipments (Q/4 AJ29-2004s) and the rule to write the technical manual of
the airplane electronics equipments(L1711-126).

1.2

This manual is appoint and legal document for the customer to repair the water system assemblyPART NO:HC -3801XAC part no:Y7-CP79-135 . This manual is satisfy for the customer to repair the water system assembly in the laboratory or a maintain factory. 1.3 water system assembly PART NO:HC -3801 XAC part no:Y7-CP79-135 , is develop by the development department of Hosun(Chengdu) Aviation Technology Co.,Ltd.

INTRO FIG.1 WATER SYSTEM ASSEMBLY FACADE

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DESCRIPTION AND OPERATION 1The System Explain 1.1 Summarize The water system assembly,part number HC-3801, mainly install on the MA60 airplane.System is consist of MAIN CONTROL SYSTEM MODULE, FAUCET ASSEMBLY and DRAIN VALVE ASSEMBLY.Among them ,MAIN CONTROL SYSTEM include an ELECTRONICS BOX ASSEMBLY, PUMP ASSEMBLY to increase press of water, electromagnetism valveFAUCET VALVE ASSEMBLY, WATER HEATER ASSEMBLY, quick conjunction contact etc.This water system assembly is to used to provide the washing service for traveller on board and aircrew. 1.2 Leading Particulars 1.2.1 The power supply consume 115 V, 400 HZs, 5 A 28 VDC 70 W 1.2.2 The airplane environment condition 1.2.2.1 High scope:-500 ms~9000 ms. 1.2.2.2 Speed scope:0~600 kms/h. 1.2.2.3 The biggest continuous flight time:8 hs. 1.2.2.4 The temperature scope while shut down:-55 ~+70 . 2 Work Principle While power on, the system automatically examines water level and water temperature in the WATER HEATER ASSEMBLY .When the water level is not enough, the system doesn't starts heating, but start to fill the water into the WATER HEATER ASSEMBLY first.till the WATER HEATER ASSEMBLY is full.When the system examines water level enough, and then examine water temperature again.If in the normal temperature mode, the system won't heat.Under 35 modes:If the temperature of water from the faucet aerator is be low at 35 , the system heats for water in the WATER HEATER ASSEMBLY, and remain to carry on a monitor to the water temperature in the WATER HEATER ASSEMBLY, promise the water temperature from the faucet aerator is at 355. While pressing the button on the faucet, the faucet aerator has silk water to rush out, and auto open DRAIN VALVE ASSEMBLY to drain sewage. In need not time, put the "DISCHARGE" switch to "ON" ,and the system auto discharge the water in WATER HEATER ASSEMBLY into the water tank.

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SYSTEM EXPLAIN FIG.1. HC-3801 WATER SYSTEM ASSEMBLY PANE SCHEMATICS

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TESTING AND FAULT ISOLATION 1Test a Condition 1.1 Temperature:+15 +R35 , Humidity : 85%, Pressure 84~107 Kpa 1.2 The connector of system and the power supply are under the good condition. 2Test Procedure 2.1 Such as Figure 2 Link an Equipments. The system explains figure1001. Test connection diagram

FIG.1001TEST CONNECTION DIAGRAM

2.2 Examine the Power On 2.2.1 Pull the "28 VDC-ON" switch on the ELECTRONICS BOX ASSEMBLY toward"ON", the power supply indicator"IND" fulgurate. 2.3The Water Level Examination 2.3.1The system in use, should have been examine the water level in the WATER HEATER ASSEMBLY. A.When water level isn't enough, the system automatically fills with water, the system

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consumes direct current electric current and should not be more than 2.5 A. 2.4 The Water Temperature Control 2.4.1The system is divided into normal temperature with 35 modes, from the ELECTRONICS BOX ASSEMBLY ascend 115 VAC the power switch carry out. A.Normal temperature mode:115 VAC the power switch place at"OFF", and the system must not heat the water in the WATER HEATER ASSEMBLY. B.35 modes:The 115 VAC power switch pulls "ON" position, the system promises the faucet aerator water temperature at 35 s 2 : C.The WATER HEATER ASSEMBLY empress with full water, the water temperature carries on an examination in the work the hour the system always the rightness the WATER HEATER ASSEMBLY. When the faucet aerator water temperature is below at 35 , the system heats for water in the WATER HEATER ASSEMBLY, heating to consume a 115 VAC electric current should be in 4.5 0.5A, and the indicator"HEATING" fulgurate. The water temperature degree arrives after 35 ,system should stop the heating,and the indicator should put out. D.The system rule value scope at the temperature should have been carry on water temperature supervision in the whole flight to promise water in the WATER HEATER ASSEMBLY inside. E.While stopping use the WATER SYSTEM, close heating to put the AC power switch of the 115 VAC/400 hz. Off. Notice:System works for 20 minutes around, can not examine change of the temperature appearance, will automatically recognize tacitly it be the normal temperature mode, and close heat circuit;If want to choose 35 modes again, must close the "28 VDC " switch ,and then open it to reset the system, at the same time, pull the 115 VACpower switch to "ON" position(upward). 2.4.2 Over Hot Protection A.With no water In the WATER HEATER ASSEMBLY, exterior to heat the part of WATER HEATER ASSEMBLY close to over hot protection switch. B.While the surface temperature of WATER HEATER ASSEMBLY more than 50 5 , the over hot protection switch should break off. C.If once needed heat protection switch resume, should press the button on the hot protection switch after the WATER HEATER ASSEMBLY cooling, make it again close. 2.5 Washing Water Control 2.5.1 Washing Hand Water Control A.Press "PUSH-" switch on the faucet, the faucet aerator should have a silk form water to rush out;keeping on 5 seconds,then stop.The capacity of the water from the faucet aerator in 5 seconds should be no smaller than 100 mls. B.After the water rinse stop in 2 seconds,The system again opens the faucet to turn on water to flush washstand ,and keeps opening 1 seconds.

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C.At this time, 1 washing water control circulation end. D.While again pressing to "PUSH-" switch on the fauce will trigger a new washing water control circulation beginning. 2.5.2 The system opens the DRAIN VALVE ASSEMBLY in the meantime while washing water control circulation ,and draw off all the sewage in the washstand in a circulation internal. 2.6 The System Discharge to Empty A.Pull the "DISCHARGE" switch on the ELECTRONICS BOX ASSEMBLY to"ON", the system auto discharge the water in its inner parts to the water tank, the power supply indicator"IND" flickers, keeps on1.5 minutes,then stops. B.Again put the "DISCHARGE" switch to "OFF", the system re-charge water, and start a new work circulation. 2.7 Close System: A.Place the 115 VAC power switch and the 28 VDC" power switch at"OFF", the system close and the power supply indicator"IND" put out.End a system work.

FIG.1002. TEST SET UP

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3Testing Record
TABLE 1001.WATER SYSTEM ASSEMBLY TESTING RECORD P/N DATE TEMPERATURE NO 1 TEST PROCESS AND CONTENT S/N PLACE HUMIDITY CHARACTERISTIC PRACTICALI -TY DATA

Pull the "28 VDC" switch on the ELECTRONICS the "IND" light be BOX ASSEMBLY to"ON", the indicator"IND" should fulgurate fulgurate The system fills with water.When the pump works, the depletion electric current of the system should not be more than 2.5 A Till the WATER HEATER ASSEMBLY be charge full, expend time should not be more than 2 minutes 2.5A

2 minute

Pull the "115 VAC" switch on the ELECTRONICS the "HEATING" light BOX ASSEMBLY to"ON", the system start to heat, fulgurate and the indicator"HEATING" fulgurate . When the system work in heating state, the current of 115 VACses/400 Hz power should not be more than 5 A. When the system stop heat, the indicator"HEATING" should put out The heating stop, the faucet aerator water temperature protect temperatures of switch on The WATER HEATER ASSEMBLY Press the "PUSH- " switch on the FAUCET ASSEMBLY, silk form water rushs out from the faucet aerator The time for the water rushing out And the capacity of the water from the faucet aerator in 5 seconds After rinse stop, the time for the system again opens the faucet to turn on water to flush washstand The time keep on for the FAUCET ASSEMBLY open to flush washstand 5A The "HEATING" light put out 355 505 silk form water rushs out 50.5s 100ml

5 6 7 8 9 10 11

12

20.5s

13

10.5s

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14

15

Press the "-DRAIN" switch behand on the FAUCET ASSEMBLY s back, the DRAIN VALVE ASSEMBLY should open to eject the sewage in the washstand;Release the switch, the DRAIN VALVE ASSEMBLY should close Pull the "DISCHARGE" switch on the ELECTRONICS BOX ASSEMBLY to"ON", the system auto exhaust the water in its inner parts toward the water tank the power supply indicator"IND" flickers The time for exhaust the water The system shut down appearance TEST EQUIPMENT

PASS

PASS The "IND" flicker light

16 17 18

1.50.5minute The "IND" light put out

NO 1 2 3 4 5 6 7

EQUIPMENT DC amperemeter Ac amperemeter Measuring Graduate Stopwatch

TYPE/ SPECIFICATION 05A 05A 250ml Commonly

TOLERANCE SPECIFICATI ON 0.1A 0.1A 10ml 0.1S 2 QUALITY ASSURER PRACTICA LITY 0.01A 0.01A 5ml 0.1S 2

PASSED CARD NO.

Thermometer TM-902C Intermediate Frequency Power YL400ZP Supply DC Power Supply 28Vdc,10A

TEST BY

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4Fault Isolation

Table1002 Fault Isolation

FAULT PROBABLE CAUSE The exterior power supply openned The IND The power switch on ELECTRONICS BOX indicator isn't ASSEMBLY openned fulgurate and water The INDindicator is bad;The 28 VDC pump doesn't work power supply fuse resistance burn;The power supply electric circuit is other to breakdown CORRECTION Unclose the exterior power supply or Replace the exterior power supply Unclose the switch Repair or replace ELECTRONICS ASSEMBLY a new BOX new BOX

The IND Replace a water level switch indicator fulgurate The water level switch is fault and water pump the PUMP ASSEMBLY blocks to the Clean the PUMP ASSEMBLYs ELECTRONICS BOX ASSEMBLY break doesn't work pipeline down The PUMP ASSEMBLY destroys The temperature sensor is fault 35 mode, the HEATING indicator don't fulgurate, don't heat The temperature protector open The temperature protector is fault Heat component is fault Replace the PUMP ASSEMBLY Replace the temperature sensor reclose protector the temperature

Repair or replace ELECTRONICS BOX ASSEMBLY is ELECTRONICS fault:CPU or water pump control circuit track ASSEMBLY

Replace a temperature protector Replace to heat component the BOX

ELECTRONICS BOX ASSEMBLY is Repair, replace fault:The HEATING light burn;CPU or ELECTRONICS heating circuit parts is fault ASSEMBLY The temperature sensor is fault The heat component is fault Replace to heat component

35 mode, the HEATING indicator fulgurate, the water temperature is too low

Replace the temperature sensor

Repair or replace In the ELECTRONICS BOX ASSEMBLY, ELECTRONICS circuit for temperature sets is fault ASSEMBLY

the BOX

35 mode, the The temperature sensor is fault Replace the temperature sensor HEATING In the ELECTRONICS BOX ASSEMBLY, Repair or replace the indicator circuit for temperature sets is fault ELECTRONICS BOX

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fulgurate,but the water temperature is too high 35 mode, the HEATING indicator fulgurate, but heat time is too Heat component is fault long, or heat current is unqualified The water tank has no water The "PUSH-" button destroys "PUSH-" button leads destroy The ELECTRONICS BOX ASSEMBLY is Press"PUSh- " fault,include:The CPU, water PUMP button, no water ASSEMBLY control circuit, or FAUCET come out VALVE ASSEMBLY control circuit FAUCET VALVE ASSEMBLY blocks or destroys The PUMP ASSEMBLY blocks or destroys

ASSEMBLY

Replace to heat component

The water tank fills with water Replace the "PUSH-" button Replace "PUSH- " button leads Repair, or replace the ELECTRONICS BOX ASSEMBLY Clean or replace theFAUCET VALVE ASSEMBLY Clean the PUMP ASSEMBLYs pipeline ,or replace the PUMP ASSEMBLY

One of these parts blocks up : the filter net in fitting which connects to the water bank,or clean the correspond part the filter net in the inlet of FAUCET VALVE ASSEMBLY ; the faucet aerator Clean the PUMP ASSEMBLYs the capacity of the The PUMP ASSEMBLY blocks or destroys pipeline ,or replace the PUMP water from the ASSEMBLY faucet aerator is Repair, or replace the too little the power supply for the ELECTRONICS ELECTRONICS BOX BOX ASSEMBLY is too low ASSEMBLY the circiut to contol the rev of PUMP Repair, or replace the ASSEMBLY in The ELECTRONICS BOX ELECTRONICS BOX ASSEMBLY is fault ASSEMBLY he capacity of the water from the faucet aerator is too much The PUMP ASSEMBLY is fault Replace the PUMP ASSEMBLY the circiut to contol the rev of PUMP Repair, or replace the ASSEMBLY in The ELECTRONICS BOX ELECTRONICS BOX ASSEMBLY is fault ASSEMBLY

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The time for the The CPU in the ELECTRONICS BOX water rushing out ASSEMBLY is fault is fault The circiut to control the DRAIN VALVE The DRAIN VALVE ASSEMBLY in the ELECTRONICS BOX ASSEMBLY ASSEMBLY is fault doesn't act The DRAIN VALVE ASSEMBLY blocks or is fault Press the " -DRAIN" switch behand on the FAUCET ASSEMBLY s back, the DRAIN VALVE ASSEMBLY doesn't act the "-DRAIN" switch is fault the "-DRAIN" switch leads destroy

Repair, or replace the ELECTRONICS BOX ASSEMBLY Repair, or replace the ELECTRONICS BOX ASSEMBLY clean or replace the DRAIN VALVE ASSEMBLY Replace the " -DRAIN" switch Replace the " -DRAIN" switch leads

Repair,or replace the Leads destroy inside the ELECTRONICS ELECTRONICS BOX BOX ASSEMBLY ASSEMBLY Replace the DRAIN VALVE The DRAIN VALVE ASSEMBLY is fault ASSEMBLY Place the In the ELECTRONICS BOX ASSEMBLY, Repair, or replace the DISCHARGE CPU or The circiut to control PUMP ELECTRONICS BOX switch to ON ASSEMBLY is fault ASSEMBLY position, the IND light is flickers , the Repair or Replace the PUMP The PUMP ASSEMBLY is fault system doesn't ASSEMBLY drain. Place the DISCHARGE switch to ON Repair, or replace the The ELECTRONICS BOX ASSEMBLY is position, the IND ELECTRONICS BOX fault, especially the CPU . light isn't flickers ASSEMBLY and the system doesn't drain.

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DISASSEMBLY 1General 1.1 Refer to TESTING AND FAULT ISOLATIONto determine extent of disassembly required . Disassemble the part of the system only to the extent necessary to accomplish repairs and return unit to serviceable condition 1.2 Refer to IPL figures for item numbers. CAUTION: DISASSEMBLE THE SYSTEM IN A CLEAN,DUST-FREE AREA. 1.3 Tools TABLE 3001.TOOLS LISTING TYPE/ SPECIFICATION ITEM TOOL SOURCE 1 Open end wrench Usual series Commercially available +screwdriver 2 Usual series Commercially available - screwdriver Usual series 3 Commercially available Usually 4 Knife Commercially available Hosun(Chengdu) Aviation 5 Faucet special tool HC3801-GJ-LT-01 Technology Co.,Ltd Deep socket 17#19# 6 Commercially available wrench Hosun(Chengdu) Aviation Wrench for drain 7 HC3801-GJ-WU-01 Technology Co.,Ltd valve coping 8 Box wrench Usual series Commercially available Usually 9 Soldering iron Commercially available Usually 10 Scissors Commercially available 2. Disassemble the System to Subassembly 2.1 The FAUCET ASSY (IPL1-370) Separates From the System 1) Turn off CONNECTOR P3 (IPL2-160) of the FAUCET ASSY (IPL1-370) from the RECEPTACLE J3 (IPL5-40) of the ELECTRONICS BOX ASSY (IPL1-270) C.C.W. 2) Turn off the NUT (IPL2-100) of the FAUCET ASSY (IPL1-370) from the outlet of the ELBOW (IPL1-230); pull off the WATER-PIPE (IPL2-110). 3) After the two step above, can realize the separating the FAUCET ASSY (IPL1-370) from the system 2.2 Separating of the DRAIN VALVE ASSY (IPL1-380) 1) Turn off CONNECTOR P2 (IPL3-90) of the DRAIN VALVE ASSY (IPL1-380) from the RECEPTACLE J2 (IPL5-30) of the ELECTRONICS BOX ASSY (IPL1-270) C.C.W. 2) After the two step above, can realize the separating the DRAIN VALVE ASSY (IPL1-380) from the system WARNING: DO NOT TURN THE PLASTICS JACKET OF THE CONNECTOR P2 AND P3, BUT THE HEAD WHICH HAS STRAIGHT ROLL VEINS. 3. Disassemble the Main Control System 3.0 Screw off the two SELF-LOCKING NUT (IPL5-190) on the TB2 (IPL5-60), remove the two WASHER (IPL5-200), the PROTECT COVER (IPL5-100) and the two COLUMN INSULATOR THIMBLE (IPL5-280).

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3.1 Separate the PUMP ASSY (IPL1-90) 1) Unscrew the screws in the connecter 5, 6, 7 and 8 of the TB2, remove the connect patch TB2-5, TB2-6, TB2-7 and TB2-8 (IPL7-40) of the PUMP ASSY (IPL1-90) .Screw back the four screws. 2) Turn off the two NUTS (IPL1-40) from the INLET ELBOW (IPL1-60) and OUTLET FITTING (IPL1-70) of the FAUCET ASSY (IPL1-370); pull off the WATER-PIPE (IPL1-50, 80). 3) Screw off the four M4 ROUND HEAD SCREWS (IPL1-280) and four M4 NUTS (IPL1-290). At the same time, remove the four SPRING WASHERS (IPL1-300) and eight WASHERS (IPL1-130).Take away the four DAMPING CUSHIONS (IPL1-110).Then can take down the PUMP ASSY (IPL1-90). 4) Turn the OUTLET FITTING (IPL1-70) C.C.W. to disassemble it from the PUMP ASSY (IPL1-90) 5) Cut a knife into place between the NAMEPLATE (IPL7-50) and the PUMP ASSY (IPL1-90) to pick off the NAMEPLATE (IPL7-50) of the PUMP ASSY (IPL1-90). 3.2 Separate the WATER HEATER ASSY (IPL1-140) 1) Turn off CONNECTOR P1 (IPL4-90) of the TEMPERATURE SENSORSNS1 (IPL4-70) from the RECEPTACLE J1 (IPL5-20) of the ELECTRONICS BOX ASSY (IPL1-270) C.C.W. WARNING: DO NOT TURN THE PLASTICS JACKET OF THE CONNECTOR P1, BUT THE HEAD WHICH HAS STRAIGHT ROLL VEINS. 2) Unscrew the screws in the connecter 1 and 2 of the TB2, remove the CONNECT PATCH TB2-1 and TB2-2 (IPL4-140) of the WATER LEVEL SWITCH (IPL4-40) FS1 .Screw back the two screws. 3) Unscrew the screws in the connecter 9 and 10 of the TB2, remove the CONNECT PATCH TB2-9 and TB2-10 (IPL4-140) of the HEATER COMPONENT HT1 (IPL4-30) .Screw back the two screws. 4) Turn off the NUT (IPL1-40) from the outlet elbow of the WATER HEATER ASSY (IPL1-140); pull off the WATER-PIPE (IPL1-180). 5) Loose the two locking screws of the CLAMP HOLDER (IPL1-150) by turning C.C.W... Take down the WATER HEATER ASSY (IPL1-140). 3.3 Separate the FAUCET VALVE ASSY (IPL1-190) SV1 1) Unscrew the screws in the connecter 3 and 4 of the TB2, remove the connect patch TB2-3 and TB2-4 (IPL1-195) of the FAUCET VALVE ASSY (IPL1-190) .Screw back the two screws. 2) Screw off the two M5 ROUND HEAD SELF-LOCKING SCREWS (IPL1-210). Remove the two WASHERS (IPL1-220). 3) Screw off the two screws (IPL1-250) from the OUTLET ELBOW (IPL1-230). Remove the two WASHERS (IPL1-260) and the ALUMINUM BLOCK (IPL1-240). 4) Turn off the NUT (IPL1-40) from the INTLET FITTING (IPL1-200) of the FAUCET VALVE ASSY (IPL1-190); pull off the WATER-PIPE (IPL1-180) 5) Turn off the INTLET FITTING (IPL1-200) and the OUTLET ELBOW (IPL1-230) C.C.W... 6) Pick off the nameplate (IPL1-340) of the FAUCET VALVE ASSY (IPL1-190) Note: Generally, the CONNECT PATCH (IPL1-195)should be dismantled no longer,

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such as need to be replace because of the damage, should be send to the maintain factory appointing by production factory. 3.4 Separate the CLAMP HOLDER (IPL1-150) 1) Screw off the eight ROUND SCREWS (IPL1-120) of the two CLAMP HOLDER(IPL1-150) ,remove the four WASHERS (IPL1-130) and the four DAMPING CUSHION(IPL1-170).Then can take away the CLAMP HOLDER(IPL1-150) for the WATER HEATER ASSY (IPL1-140). 2) Take down the five PTFE RUBBER GROMMETS (IPL1-160) on the CLAMP HOLDER (IPL1-150). 3.5 Separate the ELECTRONICS BOX ASSY (IPL1-270) 1) Unscrew the screws in the connecter 11 and 12 of the TB2, remove the CONNECT PATCH TB2-11 and TB2-12 (IPL1-195) of the CABLE (IPL1-315) connecting to the CONNECTOR (IPL1-310) P7 with the BACK SHELL (IPL1-320) .Take down them, and screw back the two screws. Remove the TB2 SEAL GASKET (IPL5-280). 2) Screw off the four M4 ROUND HEAD SCREWS (IPL1-280) and four M4 NUTS (IPL1-290) for the ELECTRONICS BOX ASSY (IPL1-270). At the same time, remove the four SPRING WASHERS (IPL1-300) and eight WASHERS (IPL1-130).Take away the four DAMPING CUSHIONS (IPL1-110).Then can take down the ELECTRONICS BOX ASSY (IPL1-270). 3.6. Other 1) Pick off the DAMPING CUSHION (IPL1-330) from the BACK PLATE (IPL1-20). 2) Pick off the NAMEPLATE (IPL1-360) from the BACK PLATE (IPL1-20). 4. Disassemble the FAUCET ASSY (see IPL2) 1) Turn off the COPING (IPL2-20) C.C.W. with a FAUCET SPECIAL TOOL (HC3801-GJ-LT-01). Loosen the packing screws of thePUSH- BUTTON PB1(IPL2-120) on the faucet ASSY C.C.W. with a - word screwdriver. Remove the end of the FAUCET CABLE (IPL2-150). 2) Turn off the locking nut of the button PB1 (IPL2-120) with a 19# deep socket wrench. Take down the button PB1.And turn the locking nut back to the button PB1. 3) Loosen the packing screws of the -DRAINBUTTON PB2(IPL2-120) on back of the FAUCET ASSY C.C.W. with a- word screwdriver. Remove the end of the FAUCET CABLE(IPL2-150) .Put the FAUCET CABLE(IPL2-150) aside, together with the CONNECTOR P3(IPL2-160). 4) Turn off the locking nut of the BUTTON PB2 (IPL2-120) with a 19# deep socket wrench. Take down the button PB2.And turn the locking nut back to the button PB2. 5) Turn off the SPRAY MOUTH SCREW CAP (IPL2-60) C.C.W. from the BACKBONE (IPL2-40) with a 17# open end wrench. Remove the SPRAY MOUTH (IPL2-50) and the outside SUPPORT (IPL2-80). 6) Remove the BACKBONE (IPL2-40) together with WATERPIPE (IPL2-110) from the inner of the faucet HOUSING (IPL2-30). 7) Turn off the LOCKING NUT (IPL2-100) from the inner FITTING (IPL2-90) of the FAUCET ASSY (IPL1-370), pull off the WATER-PIPE (IPL2-110).Remove the water-pipe and put it aside. 8) Turn off the inner FITTING (IPL2-90) .C.C.W.. Separate the inside SUPPORT (IPL2-70) with the BACKBONE (IPL2-40).

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9) Move the plastics jacket of the CONNECTOR P3(IPL2-160) back toward the electric cable bottom .Loosen the packing screw in the back shell of the connector p3 with a - word screwdriver. And remove the back shell from the connector p3 by turning the back shell C.C.W. Solder down the wires from the connector p3, and separate the CABLE (IPL2-150) with the connector p3. 10) Pick off the NAMEPLATE (IPL2-190) from the inner of the faucet HOUSING (IPL2-30). 5. Disassemble the DRAIN VALVE ASSY (see IPL3) 1) Remove the SCREEN (IPL3-60).Holding the ADAPTER (IPL3-40) of the DRAIN VALVE ASSY (IPL3-10), insert the WRENCH FOR DRAIN VALVE COPING (HC3801-GJ-WU-01) into the craft slot of the upside FITTING (IPL3-30). Turn off the upside fitting CCW. Remove the DRAIN VALVE ASSY (IPL3-10) from the washstand. Take away the upside FITTING (IPL3-30) and the GASKET (IPL3-70). Note: Generally, no longer disassemble the upside FITTING (IPL3-30) or underside FITTING (IPL3-50) from the MOMENTVALVE SV2 (IPL3-20). Such as need to be replace because of the damage, should be send to the maintain factory appointing by production factory. WARNING: WHILE REMOVING AND INSTALLING THE DRAIN VALVE ASSY, SHOULD HOLD THE ADAPTER (IPL3-40) TIGHTLYTO PREVENT LOOSEING THE CONJUNCTION BETWEEN THE ADAPTER(IPL3-40) WITH THE INLET OF MOMENTVALVE SV2 (IPL3-20). 2) Move the plastics jacket of the connector p2 (IPL3-90) back toward the electric cable bottom Loosen the packing screw in the back shell of the connector p2 with a - word screwdriver. And remove the back shell from the connector p2 by turning the back shell C.C.W. Solder down the wires from the connector p2, and separate the cable (IPL-80) with the connector p2. 3) Pick off the NAMEPLATE (IPL3-100) from the MOMENTVALVE SV2 (IPL3-20). 6. Disassemble the WATER HEATER ASSY (see IPL4) 1) Turn off the two LOCKING NUTIPL4-110,Remove the two WASHER (IPL4-160), the PROTECT COVER(IPL4-150) and the two COLUMN INSULATOR THIMBLE (IPL4-130). 2) Solder down the wire of the HEATING COMPONENT HT1 (IPL4-30) from the lead of the TEMPERATURE PROTECTOR (IPL4-100).Remove the TEMPERATURE PROTECTOR (IPL4-100) and the CABLE (IPL4-120) with the connect PATCH (IPL4-140).Clean the back of the TEMPERATURE PROTECTOR (IPL4-100).Solder down the wire with the connect PATCH (IPL4-140). Note: Generally, no longer disassemble the wire with the CONNECT PATCH (IPL4-140) soldering on the TEMPERATURE PROTECTOR (IPL4-100). 3) Turn off the HEATING COMPONENT HT1 (IPL4-30) from the heating WATER TANK (IPL4-20), with the CONNECT PATCH (IPL4-140). Store them together. Note: Generally, no longer disassemble the CONNECT PATCH(IPL4-140) from the wire of the HEATING COMPONENT HT1(IPL4-30), such as need to be replace because of the damage, should be send to the maintain factory appointing by production factory. 4) A. Turn off the TEMPERATURE SENSOR SNS1 (IPL4-70) from the heating WATER TANK

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(IPL4-20) together with the CONNECTOR P1 (IPL4-90). Store them together. B. Move the plastics jacket of the CONNECTOR P1 (IPL4-90) back toward the electric cable bottom .Loosen the packing screw in the back shell of the connector p1 with a- word screwdriver. And remove the back shell from the connector p1 by turning the back shell C.C.W. Solder down the wires from the connector p1,and separate the cable of the TEMPERATURE SENSOR SYSTEM SNS1 (IPL4-70) with the connector p1. 5) A. Disassemble the WATER LEVEL SWITCH FS1 (IPL4-40) with turning the TRANSITION FITTING (IPL4-60) CCW. B. Remove the CLIP (IPL4-46) on the forepart of the WATER LEVEL SWITCH FS1 (IPL4-40).Take down the FLOATER (IPL4-42) from the BEANPOLE (IPL4-44). C. Turn off the NUT (IPL4-48) by holding the BEANPOLE (IPL4-44) with the 17# deep socket wrench. Remove the BEANPOLE (IPL4-44) and the SEAL GASKET (IPL4-50) through the TRANSITION FITTING (IPL4-60).Take down the SEAL GASKET (IPL4-50). Note:1. Generally, no longer disassemble the CONNECT PATCH (IPL4-140) from the wire of the BEANPOLE (IPL4-44). Such as need to be replace because of the damage, should be send to the maintain factory appointing by production factory. 2. Should record piece of SEAL GASKET (IPL4-50), if need to be replace, the amount should correspond 6) Pick off the NAMEPLATE (IPL4-170) from the heating WATER TANK (IPL4-20) 7. Disassemble the ELECTRONICS BOX ASSY (see IPL5) 1) Screw off the two SELF-LOCKING NUTS (IPL5-190) on the TB2 (IPL5-60), remove the two WASHERS (IPL5-200), the PROTECT COVER (IPL5-100). Disassemble each connect patch according to step 3.1.1), 3.2. 2), 3.2. 3), 3.3. 1), 3.5. 1).Then removes the TB2 SEAL GASKET (IPL5-280) 2) Screw off the two SELF-LOCKING NUTS (IPL5-190) on the TB1 (IPL5-50), remove the two WASHERS (IPL5-200), the PROTECT COVER (IPL5-110) and the two COLUMN INSULATOR THIMBLES (IPL5-270). 3) Screw off the eight FLAT HEAD SCREWS (IPL5-220) on the SIDE COVER (IPL5-140), remove the SIDE COVER (IPL5-140). 4) Screw off the FLAT HEAD SCREW(IPL5-220) on the 9 pin CONNECTOR P1 (IPL5-290) and the 15 pin CONNECTOR P2(IPL5-300) .Pull off the 9 pin CONNECTOR P1 (IPL5-290) and the 15 pin CONNECTOR P2(IPL5-300). 5) Unscrew the five screws in the TERMINAL BOARD ASSY CN202 (IPL6-110), and remove the five connect patches. Screw back the five screws. Divide the ELECTRONICS BOX ASSY into two parts. 6) Remove the three FLAT HEAD SCREWS (IPL5-150), the three NUTS (IPL5-180) and the three WASHERS (IPL5-200) from the PCB (IPL5-10). 7) Pull out the PCB (IPL5-10) from the holding slot of the underside COVER (IPL5-130). Separate the PCB (IPL5-10) with the underside COVER (IPL5-130).Store them discretely. 8) If that demand, turn off the four install BOLT (IPL5-160) of the 9 pin CONNECTOR P1 (IPL5-290) and the 15 pin CONNECTOR P2(IPL5-300). 9) Take off the insulate material and tie string on the feet of the 115vpower source SWITCH

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SW201 (IPL5-260).Unscrew the screws on the feet. Take off the connect patches, at same time screw back the five screws to store. Turn off the locking nut of the SWITCH SW201 (IPL5-260), remove the directional washer, take down the SWITCH SW201 (IPL5-260) from the inner of the UPSIDE COVER (IPL5-120).Assemble back the install nut to prevent losing. 10) A. Take off the insulate material and tie string on the feet of the 28 VDC SWITCH SW1 (IPL5-70) .Solder down the lead from the feet. Turn off the install nut, remove the locking washer and the directional washer, take down the SWITCH SW1 (IPL5-70) from the inner of the upside COVER (IPL5-120).Assemble back the install nut to prevent losing. B. Take off the DISCHARGE SWITCH SW2 (IPL5-80) according to the same method as step A. 11) A. Take off the insulate material and tie string on the feet of the ECEPTACLE J1 (IPL5-20) .Solder down the lead from the feet. Turn off the install nut, remove the washer, take down the ECEPTACLE J1 (IPL5-20) from the outside of the upside COVER (IPL5-120).Assemble back the install nut to prevent losing. B. Take off the ECEPTACLE J2 (IPL5-30) and ECEPTACLE J3 (IPL5-40) according to the same method as step A. 12) A. Take off the insulate material and tie string on the feet of the LAMP HOLDER (IPL5-90) .Solder down the lead from the feet. Turn off the install nut, remove the locking washer and flat washer, take down the LAMP HOLDER (IPL5-90) from the outside of the upside COVER (IPL5-120).Assemble back the install nut to prevent losing. B. Turn off the black nonmetal lamp-socket CCW and separate the LAMP HOLDER (IPL5-90) into lamp-socket and lampshade. Snip the feet of the LED DS1 (IPL5-240) and the LED DS202 (IPL5-250), take out the LED from the lamp-socket, and discard them. 13) A. Cuts off tie string on the lead of the TERMINAL BOARD ASSY TB1-2(IPL5-50). Solder down the lead from the feet. Unscrew the flat head SCREW(IPL5-170) to steady TERMINAL BOARD ASSY TB1-2 (IPL5-50) ,remove the M3 NUTS(IPL5-180) and SPRING WASHERS (IPL5-210).Take down the TERMINAL BOARD ASSY TB1-2 (IPL5-50) from the outside of the upside COVER (IPL5-120). B. Take off the TERMINAL BOARD ASSY TB2-12 (IPL5-60) according to the same method as step A. 14) Solder down the lead from the feet of the 9 pin CONNECTOR P1 (IPL5-290) and the 15 pin CONNECTOR P2(IPL5-300). 15) Pick off the NAMEPLATE (IPL5-230) from the outside surface of the UPSIDE COVER (IPL5-120) WARNING: SHOULD TAKE AN ANTI-ELECTROSTATIC PROTECTION WHEN CONTACTING THE PCB ASSY (IPL5-10).

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CLEANING 1General 1.1 The cleaning for the WATER SYSTEM ASSEMBLY , divided into the system is in use without take down from the airplane; or the system is disassembled. 1.2 Cleaning Materials TABLE 4001CLEANING MATERIALS MATERIA Brush,Stiff Bristle,Non-Metallic Cloth,Lint-Free Detergent,Dishwashing Liquid Depurative, Tableware Isopropyl Alcohol Clean Water 2Cleaning Procedures WARNING:SHOULD USE ALCOHOL IN THE WELL VENTILATED AREA TO ENSURE EVACUATION OF FUMES AND AVOID INHALATION OF FUMES, KEEP ALCOHOL AWAY FROM OPEN FLAMES; PREVENT TO GET ALCOHOL INTO PERSON'S EYES, MOUTH OR NOSE. CAUTION:DO NOT IMMERSE ELECTRICAL COMPONENTS IN ANY CLEANING LIQUID. 2.1 Cleaning with the System is in Use 2.1.1Cleaning the Furring in the MAIN CONTROL SYSEM and the FAUCET ASSY 1) Method 1 (1) Prepares 2 Ls detergent solution according to the factory elucidation. (2) put the solution into a narrow edge container. (3) Place container to spray mouth position of the FAUCET ASSY, and the spray mouth immerge into the aqueous solution. (4) Open the system"28 VDC" power supply.Place the"DISCHARGE" switch at "ON" position.Lets the system Inhales the aqueous solution.untill automatically stop by the system.Place the"DISCHARGE" switch at "OFF" position. (5) Open 115 VAC power supply, and the 115 VAC switch on the ELECTRONICS BOX ASSEMBLY place at"ON". Heat the water in the WATER HEATER ASSEMBLY,and keep it up for 30 minuteses around. SPECIFICATION Commercially Available Commercially Available Commercially Available Commercially Available 99% or Better GB57492006

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(6)Carry on 60~100 the FAUCET ASSY to turn on to make the water flow out, and make sure all the detergent solution in the system be changed by clean water. 2) Method 2 (1) Prepares 2 Ls Detergent solution according to the factory elucidation. Place in a container whose cubage is bigger than 2 L.. (2) Open the system"28 VDC" power supply.Place the"DISCHARGE" switch at"ON" position, and make sure all the water in the system be drain out. (3) Take off the fitting from the water tank out-let, and immerge the fitting into the aqueous solution. (4) And then Place the"DISCHARGE" switch to the "OFF" position, let the system draw the detergent solution into system;and allow little detergent solution flows out from the spray mouth of the FAUCET ASSEMBLY. (5) Open 115 VAC power supply, and put the 115 VACswitch on the ELECTRONICS BOX ASSEMBLY to the "ON" position . Heat the water in the WATER HEATER ASSEMBLY., and keep it up for 30 minuteses around. (6) Rinse interior of the system: Method 1: A. Place the"DISCHARGE" switch at"ON" position, drain off all the detergent solution into a container, and discard. B. Then put the inlet fitting into a container witch fills with cleanness water. Place the"DISCHARGE" switch at "OFF" position, l infuse clean water into the system.Keep it up for 3~5 minutes. C. Place the"DISCHARGE" switch at"ON" position, drain off all the solution into a container, and discard. D. Repeated step B and C 3~5 times. E. Fits the inlet fitting back to the outlet fitting of the water tank. Method 2: A. Place the"DISCHARGE" switch at"ON" position, drain off all the detergent solution into a container, and discard. B. Fits the inlet fitting back to the outlet fitting of the water tank. C. Carry on 60~100 the FAUCET ASSY to turn on to make the water flow out, infuse cleanness water into the system to rinse the interior of the system to clean. Method 3: A. Fits the inlet fitting back to the outlet fitting of the water tank. B. Carry on 60~100 the FAUCET ASSY to turn on to make the water flow out, infuse cleanness water from the water tank into the system to rinse the interior of the system to clean. 2.1.2 Cleaning the Furring in the DRAIN VALVE (1) Prepares 200 mls or mre Detergent solution according to the factory elucidation, and

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jion in 5 mls tableware depurative. Mix them to a new aqueous solution for cleaning. (2) Remove the tube from the underside fitting of the DRAIN VALVE, and plug up the underside fitting. (3) press the -DRAIN" button on the back of the FAUCET ASSY, to open the valve of the DRAIN VALVE. (4) Infuse the new cleaning solution into the pipeline of the DRAIN VALVE. (5) press the -DRAIN" button on the back of the FAUCET ASSY some times, do it to open the valve of the DRAIN VALVE some times. (6) Then let the DRAIN VALVE holds the new cleaning solution about 30 minutes. (7) Remove the water screen, then use a little non-metallic brush to brush the interior of upside fitting. Take off the plug from underside fitting of the DRAIN VALVE,and brush the interior of underside fitting. (8) Open the valve of the DRAIN VALVE, drain off all the new cleaning solution. (9) Use clean water, flush the pipeline of the DRAIN VALVE 5~7 times, in the meantime open the valve of the DRAIN VALVE several times. 2.1.3 Clean the Surface of the System (1) Use the lint-free cloth to immerse some clean water, and adequacy wring dry. (2) Use the cloth to clean all the parts surface of the system. (3) Wipe all parts surfaces to dry with a clean dry lint-free cloth;Or dry the surface of all the parts with dryclean compressed air at 5~10 psigs(35~70 Kpas) . 2.2 Clean When the System is Disassembled 1) Clean the parts along the waterway (1) Prepares some detergent solution according to the factory elucidation. (2) Protect all sects of the waterway parts which has electric circuit, immerge the sect of the waterway parts which has the Furring into the detergent solution around 30 minutes.when some dirt sects haven't soaked, can use a brush dip some detergent solution to brush it. (3) Use clean water to rinse the sects out the detergent solution to cleaning. 2) Sweep Electrical Parts (1) Wipe the surface of the electrical parts with a lint-free cloth, propriety, can dip a little amount of alcohol. (2) brush the dust and dirts in narrow area of electrical parts.Appropriate hour, propriety, can dip a little amount of alcohol. (3) Wipe all parts surfaces to dry with a clean dry lint-free cloth;Or dry the surface of all the parts with dryclean compressed air at 5~10 psigs(35~70 Kpas) . 3) Clean the Surface of the System Same as step 2.1.4).

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CHECK 1General 1.1 This section has the necessary data to check the system. 1.2 Refer to IPL Figure 1for item numbers. 2, Check Procedure NOTE: Inspect parts under the strong light and under magnification of 10 power or greater, visually examine parts for evidence of wear and/or damage . 2.1 Check all parts for cracks,corrosion,gouges,wear,and other damage or deterioration.
Discard the spare part which isCrack, damage , seriously erode or wear away .

2.2 Check threads for wear,stripping, and cross-threading.Discard the spare part that the thread is damaged. 2.3 Check the system hasn't broken line,or has no damage wirews. 2.4 Check the connectors have no bent pin. 2.5 Check the system had no leaking trace; specially repare the leaking place.

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REPAIR 1General 1.1 Repare this equipment must follow general principle, should pretect the static electricity sensitive component WARNING:The equipment include static electricity sensitive component, have to adopt anti-electrostatic measure while operate and wear very anti-electrostatic wrist. 1.2 For the system repair, generally take replacing to fault partsReplace crack, damage seriously decay or wear away spare parts;Replace the spare parts whose thread is damaged 1.3 Material TABLE 6001:REPAIR MATERIALS MATERIAL Cloth,Emery Aluminum oxide polishing cloth Lacker Cloth,Lint-Free Isopropyl Alcohol Brush,Stiff Bristle,Non-Metallic Oxidant, Aluminum Clear Enamel Paint Soldering Tin SPECIFICATION Grain Size:160 or Better, Commercially available Grain Size:240 or Better, Commercially available Black,Not Glisten; Commercially Available Commercially Available 99% or Better Commercially Available Commercially Available Commercially Available ALPHA (TELECORE PLUS)0.51MMSN63/PB37

2Repair Procedure 2.1 Replacing 1) Remove the parts need replacing according to the DISASSEMBLY procedure 2) Install the new parts according to the ASSEMBLY procedure

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2.2 Repair the part which is slightly decay, wear away or minor nicks and scratches 1) Nonmetal part which is slightly worn away and scraped ,dosnt need torepair 2) For slightly wear away or scraped stainless steel parts: drawbench surface, use emery cloth to burnish along the trace of drawbench ; for the polishing surface, after burnishing with a emery cloth, polishing it. 3) For slightly wear away or scraped aluminum part: (1) Burnish the wear away or scraped area with Aluminum oxide polishing cloth, then clean the area with lint-free cloth dipping a little of isopropyl Alcohol (2) On the finishing surface of aluminum part, smearing around 0.1 thick aluminum oxidant, and wait the oxidation to be steadily according to the factory elucidation . (3) If color of the finishing surface is black, must spray a film of black lacker above the oxidizing film and wait it to be steadily according to the factory elucidation . (4) If color of the finishing surface is the self color of aluminum, must spray a film of clear enamel paint above the oxidizing film;and wait it to be steadily according to the factory elucidation . 2.3 Repair the circuit board 2.3.1 Take-down and install the device of the circuit board according to general national standard of china,andGENERAL REGULATIONSof Hosun(Chengdu) Aviation Technology Co.,Ltd.. 2.3.2 The standard soldering of the Electronical device should meet the following request: (1) The solder joint is inflexed arc-shaped. (2) The solder joint must be round, smooth, no pinhole or l rosin dross. (3) Have wire feet, and the length of wire feet must be between 1 to 1.2 . (4) The soldering tin around device feet shape flows to spread freely. (5) The soldering tin surrounds the whole soldering dot and device feet. 3. Repair the mark of TB1-2 and TB2-12 1) Clean up the damaged mark of TB1-2(IPL5-50) or TB2-12(IPL5-60). 2) Clean the affix face of TB1 and TB2; smearing around 0.1 ~0.2 thick film of two-component epoxyn (mixture compare according to elucidation of the material factory, suggestion adoption the type which solidify soon ) on the side with no word of the aluminum slice mark. 3) A. Affix the mark to inside the slot of the side face.The word direction of TB1-2(IPL5-50) perpendicularity points to the outside of the ELECTRONICS BOX ASSEMBLY upperside cover(IPL5-120);The sequence of word is from up to bottom. B. The word direction of TB2-12(IPL5-60) perpendicularity points to the intside of the ELECTRONICS BOX ASSEMBLY upperside cover(IPL5-120);The sequence of word is from left to right .

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ASSEMBLY 1. General 1.1 Before starting to assemble the unit,must read through and be familiar with the entire assembly procedure.Pay particular attention to all WARNINGS and Notes . 1.2 Refer to TESTING section after unit is assembled.And refer to IPL Figures for item numbers. Note: Assemble the MAIN CONTROL SYSTEM in a clean,dust-free area. 2. Assembly Materials Explain: Equivalent alternatives may be used for listed items. TABLE7001. ASSEMBLY MATERIALS MATERIAL Loctite 242 Clear Protective Lacquer White Silicone Rubber Two-component Epoxyn RSFR-H Pyrocondensationin Sulating Sleeve Soldering Tin PTFE Thread Seal Tape Transfer Heat Silicone Grease Isopropyl Alcohol 3. Assembly Procedures 3.1 Assemble The ELECTRONICS BOX ASSYIPL56 3.1.1 Assemble The PCBIPL5-10 1) Before assemble the RECEPTACLE J1 and RECEPTACLE J2,must install the BOLT IPL5-160 OK first.Its screw perforate the PCB from the marking side to another side.Put on the washer(IPL5-200) respectively,screw on the nut(IPL5-180) tightly with torque 2~3 NM. 2) Install RECEPTACLE J1 and RECEPTACLE J2,and solder their pins to the PCB. 3) Though the hole of RECEPTACLE J1and J2,screw four boltsIPL5-160into the thread bore of the bolt which has installed on the PCB.Turn the bolts tightly with torque 2~3 NM. SPECIFICATION Commercially available Plasticot 70, Commercially available Commercially available Mucilage Glue,555, Commercially available Commercially available ALPHA (TELECORE PLUS) 0.51MMSN63/PB37 20 0.1 , Commercially available Commercially available 99% or Better, Commercially available

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4) Install the PCB into the UNDERSIDE COVER IPL5-130 . Make sure the side with the component far from the underside cover . 5) Install the screws(IPL5-150) though the assemble holes of the UNDERSIDE COVER IPL5-130and the PCB(IPL6-10). Put on the washer(IPL5-200) respectively ,screw on the nut(IPL5-180) tightly with torque 1~2 NM. 6) Apply some Loctite 242 to the sect thread that outcrops above the nut ,for all the screws. 3.1.2 Assemble the RECEPTACLE J1 (IPL5-20) 1) Turn off the locking nut of the receptacle J1, which has two pins. Take aside the flat washer and seal gasket. 2) Install the receptacle J1 though the hole on UPSIDE COVER (IPL5-120) from outside. In the UPSIDE COVER, put on the flat washer and seal gasket one by one. Then, turn on the locking nut with torque 1~2 NM. 3) After insuring the J1 crust is shorting to the upside cover (IPL5-120), apply some LOCTITE 242 to the thread of the receptacle J1. 3.1.3 Assemble the RECEPTACLE J2 (IPL 5-30) 1) As the step 3.1.2. 3.1.4 Assemble the RECEPTACLE J3 (IPL 5-40) 1) As the step 3.1.2. 3.1.5 Assemble the LAMP HOLDERDS1, DS2(IPL5-90) 1) Turn off the nut of the lamp holderDS1DS2.Take aside the flat washer and locking gasket. 2) Install the lamp holder though the hole on the UPSIDE COVER (IPL5-120) from outside. In the UPSIDE COVER, put on the flat washer and locking gasket one by one. Then, turn on the locking nut with torque 1~2 NM. 3) Apply little LOCTITE 242 to the thread of the lamp holderDS1, DS2(IPL5-90) 3.1.6 Assemble the Power Switch SW201(IPL5-260) 1) Turn off the locking nut of the SWITCH SW201(IPL5-260),remove the directional washer, 2) Install the switch (IPL5-260) though the install hole on the UPSIDE COVER (IPL5-120) from inside to outside. Put on the directional washer. The wedge tip must wedge into the directional rabbet beside the install hole and on the outside of the UPSIDE COVER(IPL5-120). 3) Turn on the locking nut, after insuring the SW201 crust is shorting to the upside cover (IPL5-120), screw tightly with torque 1~2 NM. 3.1.7 Assemble the Switch SW1 (IPL5-70) and the Switch SW2(IPL5-80) 1) Turn off the install nut, remove the locking washer and the directional washer from each switch. 2) Install the switch though the install hole on the UPSIDE COVER (IPL5-120) from inside to outside. Put on the directional washer, and then the locking washer. Note: Make sure the seal gasket of the switch to be installed in the inside of the

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UPSIDE COVER (IPL5-120) 3) Turn on the install nut, after insuring the SW1 and SW2 crust is shorting to the upside cover (IPL5-120) , screw tightly with torque 1~2 NM. 3.1.8 Assemble the TERMINAL BOARD ASSY TB1-2(IPL5-50) 1) Sleeve a PTFE insulative tube with longness 4 , interior diameter 3 and exterior 5 diameter onto the connect patch. Install TB1-2 on the area with TB1 mark of the UPSIDE COVER outside, and the connect patch get into the hole from outside. 2) Install two screws(IPL5-170) with washer(IPL5-200) through the hole on side of the area with TB1marking on the UPSIDE COVER(IPL5-120),together through the hole on side of the TERMINAL BOARD ASSY TB1-2(IPL5-50).Put a spring WASHER (IPL51-210) on each screw (IPL5-170), and a nut (IPL5-180).Turn the nut tightly with torque 1~1.5NM 3) Install a column INSULATOR THIMBLE (IPL5-270) onto each screw. Put on the PROTECT COVER (IPL5-110).Then put on a washer (IPL5-200) and a self-locking nut (IPL5-190) to each screw. Note: The self-locking nuts (IPL5-190) finally turn tightly by aircrew after setting the 28 VDC power cable. The torque is in 1~2 NM 3.1.9 Assemble the TERMINAL BOARD ASSY TB2-12(IPL5-60) 1) Same as step 3.1.8.1). 2) Same as step 3.1.8.2). 3) Install a column INSULATOR THIMBLE (IPL5-280) onto each screw. After setting all the feet of TB2, put on the PROTECT COVER (IPL5-110).Then put on a washer (IPL5-200) and a self-locking nut (IPL5-190) to each screw. Turn the nut tightly with torque 1~1.5 NM. 3.1.10 Assemble the LED DS1 (IPL5-240) 1) Sleeve a PTFE insulative tube with longness 6 , interior diameter 1 and exterior 2 diameter onto each foot of the LED DS1 (IPL5-240). 2) Turn off the black nonmetal lamp-socket of the lamp holder the one marks IND on the UPSIDE COVERC.C.W. Install the LED into the inner of the lamp-socket, by the LED feet getting though the bore. Make sure the LED feet sink into the inner of the black nonmetal lamp-socket. 3) Assemble back the inner of the black nonmetal lamp-socket ,and turn tightly. 4) Coil the protrusion foot round to loop whose diameter is about 2 ,and got rid of surplus sect. 5) Peel off 4 jacket from each end of a 0.35 2 red lead. Insert one end into the 2 loop. Press the loop to clip the lead end tightly, and solder them together. Solder the other end of the lead to the 4th foot of the 9-pin CONNECTOR P1 (IPL5-290). Insulate the both ends commendably with RSFR-H pyrocondensationin insulating sleeve. 6) Peel off 4 jacket from each end of a 0.35 2 black lead. Insert one end into the 2 loop. Press the loop to clip the lead end tightly, and solder them together. Solder the other end of the lead to the 8th foot of the 9-pin CONNECTOR P1 (IPL5-290). Insulate

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the both ends commendably with RSFR-H pyrocondensationin insulating sleeve. 3.1.11 Assemble the LED DS202 (IPL5-250) 1) Sleeve a PTFE insulative tube with longness 6 , interior diameter 1 and exterior 2 diameter onto each foot of the LED DS202 (IPL5-250). 2) Turn off the black nonmetal lamp-socket of the lamp holder the one marks HEATING on the UPSIDE COVERC.C.W. Install the LED into the inner of the lamp-socket, by the LED feet getting though the bore. Make sure the LED feet sink into the inner of the black nonmetal lamp-socket. Assemble back the inner of the black nonmetal lamp-socket ,and turn tightly. 3) Coil the protrusion foot round to loop whose diameter is about 2 ,and got rid of surplus sect. 4) A. Peel off 4 jacket from one end of a 0.35 2 red lead and insert the end into the 2 loop for the positive pole. Press the loop to clip the lead end tightly, and solder them together. B. Peel off 6 jacket from the other end. Insert the end into the back bore of a connect PATCH (IPL4-140). Press the loop to clip the lead end tightly, and solder them together. Insulate the both ends commendably with RSFR-H pyrocondensationin insulating sleeve. C. Connect the patch to the first foot of the TERMINAL BOARD ASSY (IPL6-110). 5) Do as the step 4) except the lead is black, and the patch is connect to the third foot. 3.1.12 Assemble the Heating Circuit Lead 1) A. Solder one end of a 0.5 2 red lead to the twelfth foot of the TERMINAL BOARD ASSY TB2-12(IPL5-60).And connect the other end to a connect PATCH(IPL4-140). Insulate the both ends commendably with pyrocondensationin insulating sleeve. B. Connect the PATCH to one side foot of the 115 V power SWITCH SW201(IPL5-260). 2) Do as the step 1) except the lead is blue. And connect the PATCH to the other side foot of the 115 V power switch. 3) A. Connect the both end of another red lead to connect PATCH (IPL4-140). Insulate the both ends commendably with pyrocondensationin insulating sleeve. B. Connect one of PATCH to the middle foot of the switch which has connected red lead .Connect the other PATCH to the fifth foot of the TERMINAL BOARD ASSY(IPL6-110). 4) A. Do as the step 3) but the lead is blue. B. Connect one of PATCH to the middle foot of the other switch which has connected blue lead .Connect the other PATCH to the fourth foot of the TERMINAL BOARD ASSY(IPL6-110). 3.1.13 Connect the Other Lead 1) Do according to the PRINCIPLE DIAGRAMsee FIG 60016002. 2) Join the lead lines according to the methods of the step3.1.12; 3) The Positive pole of DC connects is 0.35 2 red lead;

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The Negative pole of DC connects is0.35 2 black lead; The other use 0.35 2 white lead; 4) Do the damp-proofdustproof and insulating disposal to all the pontes. 3.1.14 Assemble the Crust of the ELECTRONICS BOX ASSYIPL5 1)A. place the upside COVER(IPL5-120) onto the underside COVER (IPL5-130),the edge of the upside COVER must insert into the slot of the underside cover. At the same time, should promise the direction of the 115v SWITCH (IPL5-260) on the upside cover is same as the direction of the ellipse hole on the underside cover. Keep compaction with the two cover. B. Put on the side COVER (IPL5-140), screw into four SCREWS (IPL5-220) that has smeared little LOCTITE 242 to fix upside cover, underside cover and side cover together. 2) After insuring the underside COVER (IPL5-130) is shorting to the upside cover (IPL5-120), Screw the four screws tightly with the torque 1~1.5 NM. 3.1.15 Affix NAMEPLATE(IPL5-230) 1) With lint-free cloth dipping a little of water ,clean the outside surface of the upside cover (IPL5-120) and the back of the NAMEPLATE(IPL5-230). 2) Affix the NAMEPLATE (IPL5-230) onto the upside cover (IPL5-120).Make sure the word direction of the NAMEPLATE is same as the upside cover. 3.2 Assemble The WATER HEATER ASSYIPL4 3.2.1 Fix the Heating COMPONENT HT1 (IPL4-30) 1) Wind previous 3 to 4 circles PTFE thread seal tape to the fitting threads of the HEATING COMPONENT, according to direction of thread C.W. 2) Fix the Heating COMPONENT HT1(IPL4-30) into the WATER TANK(IPL4-20) tightly with torque 6~7 NM. 3.2.2 Fix the TEMPERATURE PROTECTOR (IPL4-100) 1) Smear a film of transfer heat silicone grease on the feeling face. Install the TEMPERATURE PROTECTOR(IPL4-100),and the feeling face keeps close to the surface of the WATER TANK(IPL4-20). Install a column INSULATOR THIMBLE (IPL4-130) onto each install screw. 2) A. Take one lead of the CABLEIPL4-120whose length is in 420 5 , and sleeved with 400 5 long 3 silica gel sleeve. Sleeve its end by 6 long 3 RSFR-H Pyrocondensationin Insulating Sleeve. Shell its end 4 length. After puckering symmetrically, put the folio end into the connection hole of CONNECT PATCH (IPL4-140), tighten the connection hole, and weld them with little solder, then insulate the joint commendably with pyrocondensationin insulating sleeve B. Set the serial number tube TB2-10 to the joint end with letter t toward the CONNECT PATCH (IPL4-140). 3) Take the other lead of the CABLE with length in 400 5 , and sleeved with 380 5

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 long 3 silica gel sleeve. Shell its end 6 length, set over 20 length pyrocondensationin insulating sleeve, and put the end though the connection hole of the TEMPERATURE PROTECTOR (IPL4-100), coil tightly and weld faultlessly. Then insulate the joint commendably with 20 length pyrocondensationin insulating sleeve. 4) A. Then take the lead the CABLE with length in 4605 ,and sleeved with 440 20 long 3 silica gel sleeve. Shell off its 6 length skin, set over 20 length pyrocondensationin insulating sleeve, and put the end though the other connection hole of the TEMPERATURE PROTECTOR (IPL4-100), coil tightly and weld faultlessly. Then insulate the joint commendably with 20 length and4 pyrocondensationin insulating sleeve. Otherwise, intercept the silica gel sleeve to sleeve the lead, and envelop the two nozzle of the silica gel sleeve commendably with 4 pyrocondensationin insulating sleeve. B. Set over 6 length 3 pyrocondensationin insulating sleeve, Shell the end 6 length, after puckering symmetrically, put the folio end into the connection hole of CONNECT PATCH (IPL4-140), tighten the connection hole, and weld them with little solder, then Insulate the joint commendably with pyrocondensationin insulating sleeve. Set the serial number tube TB2-9 to the joint end, with letter t toward the CONNECT PATCH (IPL4-140), 5) Put the PROTECT COVER (IPL5-150) on the column INSULATOR THIMBLE (IPL4-130).Then put on a #3 washer (IPL5-160) and a M3 LOCKING NUT (IPL5-110) to each screw. And turn the nut tightly with torque 1~1.5 NM. 3.2.3 Install the WATER LEVEL SWITCH (IPL4-40) 3.2.3.1 Assemble the WATER LEVEL SWITCH (IPL4-40): 1) Take off the CLIP (IPL4-46), the FLOATER (IPL4-42) and the NUT (IPL4-48) of the WATER LEVEL SWITCH (IPL4-40). 2) Put on 13 seal GASKET(IPL4-50) onto the screw of the BEANPOLE(IPL4-44).Draw the screw of the BEANPOLE out though the hole of the TRANSITION FITTING(IPL4-60). Note: The quantity of the seal GASKET(IPL4-50),can adjust the distance from the top of the BEANPOLE(IPL4-44) to the install setting upper plane on upside of the water tank ,and make sure it is at 152 . 3) Tighten the NUT (IPL4-48).Assemble back the FLOATER (IPL4-42) as previously. And put back the CLIP(IPL4-46). 3.2.3.2 Install the WATER LEVEL SWITCH (IPL4-40): 1) Smear some LOCTITE 242 to the fitting thread of the TRANSITION FITTING(IPL4-60). 2) Install the WATER LEVEL SWITCH(IPL4-40) into the WATER TANK(IPL4-20) ,and turn it tightly with GASKET(IPL4-65) be compressed around 0.2mm. 3.2.4 Install The TEMPERATURE SENSOR SYSTEM (IPL4-70) 3.2.4.1 Assemble the TEMPERATURE SENSOR SYSTEM (IPL4-70):

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1) Cut short the cable of the SENSOR (IPL4-75) to promise it to 300 5 . 2) Joint the cable of the sensor into the CONNECTOR P1 (IPL4-90).Make sure the red lead connect to the first foot, and the black lead connect to the second. Insulate the joint of P1 commendably. 3.2.4.2 Install the TEMPERATURE SENSOR SYSTEM (IPL4-70): 1) Wind previous 3 and 4 PTFE thread seal tape to the thread of the FITTING (IPL4-80),according to direction of thread C.W. 2) Install the TEMPERATURE SENSOR SYSTEM (IPL4-70) into the WATER TANK (IPL4-20) and turn it tightly with torque 2~3 NM. 3.2.5 Affix NAMEPLATE (IPL4-170) 1) Affix NAMEPLATE(IPL4-170) onto the outside surface of the WATER TANK (IPL4-20),and make sure the direction of the nameplate word is upwards. 3.3 Assemble the DRAIN VALVE ASSY (IPL3) 1) Smear a film of white silicone rubber onto thread of the UNDERSIDE FITTING (IPL3-50).Fix the UNDERSIDE FITTING (IPL3-50) into the outlet of the MOMENTVALVE (IPL3-20). Get rid of the unwanted silicone rubber, and wait for it solidifies completely. 2) Smear a film of white silicone rubber onto thread of the ADAPTERIPL3-40, Fix the ADAPTERIPL3-40into the inlet of the MOMENTVALVE(IPL3-20). Get rid of the unwanted silicone rubber, and wait it solidifies completely. 3) Cut the CABLE(IPL3-80) to 50010 long. Connect it into the CONNECTOR P2(IPL3-90).Make sure to joint the red lead to the first foot, the black lead to the third and the blue lead to the second. Insulate the jointing commendably with pyrocondensationin insulating sleeve. Drop some white silicone rubber into the inner, and assemble the CONNECTOR P2 (IPL3-90) completely. 4) Put the seal GASKET (IPL3-70) onto the UPSIDE FITTING (IPL3-30) .And install the UPSIDE FITTING (IPL3-30) to the ADAPTER (IPL3-40).Put the SCREEN (IPL3-60) into the UPSIDE FITTING (IPL3-30). 5) Affix NAMEPLATE (IPL3-100) onto the surface beside the CABLE (IPL3-80), and make sure the direction of the nameplate word is right about the CABLE (IPL3-80). 3.4 Assemble the FAUCET ASSY (IPL2)
3.4.1 Assemble Water Head 1) Install the INSIDE SUPPORT(IPL2-70) on the BACKBONE(IPL2-40).Make the 8 hole of the INSIDE SUPPORT(IPL2-70) parallel to the M8 hole of the BACKBONE(PL2-40). 2) Smear a film of white silicone rubber onto the M8 thread of the INNER FITTING (IPL2-90).Install the INNER FITTING (IPL2-90) to the BACKBONE(IPL2-40),and turn tightly with 1~2 NM torque. 3) A. Put a NUT(IPL2-100) on one end of the WATERPIPE(IPL2-110).Then draw the end onto the inlet of the INNER FITTING (IPL2-90) tightly. B. Place on the Nut (IPL2-100); and turn tightly with less than 1 NM torque.

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4) A. Draw the BACKBONEIPL2-40out though the 16 tilted hole of the HOUSING

IPL2-30from the inner. IPL2-40 ,make sure B. Install the OUTSIDE SUPPORT(IPL2-80) onto the BACKBONE the camber side face to the BACKBONEIPL2-40.
C. Place a SPRAY MOUTH(IPL2-50) into the SCREW CAP(IPL2-60). the cone side face to inside. D. Smear a film of white silicone rubber onto the thread of the BACKBONEIPL2-40 Turn the SCREW CAP(IPL2-60) with a SPRAY MOUTH(IPL2-50) tightly onto the BACKBONEIPL2-40with torque 1~2 NM. Clean up the unwanted silicone rubber. 3.4.2 Assemble the Drain Valve BUTTON PB2 (IPL2-120)

1) Loose the two screw which is used to press the lead tightly on the drain valve BUTTON PB2(IPL2-120).Draw in two long lead, and turn the two screws tightly with torque 0.5 1NM. 2) A. Dismantle the locking nut from the drain valve BUTTON PB2(IPL2-120); B. Install the OUTSIDE SUPPORT (IPL2-130) onto the button PB2 (IPL2-120), and install the button PB2 (IPL2-120) into the 16 hole near the seat of the HOUSING (IPL2-30). 3) Install the INSIDE SUPPORT (IPL2-140) onto the button PB2 (IPL2-120), make sure the camber side keeps close to the inner of the HOUSING (IPL2-30). 4) Install back the locking nut onto the drain valve BUTTON PB2 (IPL2-120), and turn tightly with torque 1~2 NM. 5) Enlace the two leads steady. Seal the joint of the drain valve BUTTON PB2(IPL2-120) with enough white silicone rubber 3.4.3 Assemble the Faucet BUTTON PB1 (IPL2-120) 1) Dismantle the locking nut from the faucet BUTTON PB1(IPL2-120). 2) Install the faucet BUTTON PB1 (IPL2-120) into the COPING (IPL2-20).The keystroke of the button is toward the outside of the COPING (IPL2-20). 3) Install back the locking nut onto the faucet BUTTON PB1(IPL2-120),and turn tightly with torque 1~2 NM. 4) Loose the two screw which is used to press the lead tightly on the faucet BUTTON PB1(IPL2-120).Draw in two long lead, and turn the two screws tightly with torque 0.5 1NM. 5) Enlace the two leads steady. Seal the joint of the faucet BUTTON PB1(IPL2-120) with enough white silicone rubber 3.4.4 Assemble the COPING (IPL2-20) 1) Install the COPING(IPL2-20) to the HOUSINGIPL2-30,and pull out the leads though the HOUSINGIPL2-30from the end with thread. Make sue the lead has no knot. 2) turn the COPING(IPL2-20) tightly with FAUCET SPECIAL TOOLHC3801-GJ-LT-01. The torque is in 23NM.

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3.4.5 Deal With the CABLE (IPL2-150) and the CONTACTOR(IPL2-160) 1) Wind the leads of the faucet BUTTON PB1 and the drain valve BUTTON PB2. Sheath them together commendably with pyrocondensationin insulating sleeve. 2) Make sure the length of the CABLE(IPL2-150) above the setting face of the FAUCET is at 40010 .Connect the leads to the CONNECTOR (IPL2-160) P3,and make sure the leads of the faucet BUTTON PB1 joint to the first and second foot, the leads of the drain valve BUTTON PB2 joint to the third and fourth foot. 3) Insulate the jointing commendably with pyrocondensationin insulating sleeve. Drop some white silicone rubber into the inner, and assemble the CONNECTOR (IPL2-160) P3 completely. 3.4.6 Affix the NAMEPLATE (IPL2-190) 1) According to the step 3.1.15 ,Affix NAMEPLATE(IPL2-190) onto the inner near the seat of the HOUSINGIPL2-30and make sure the direction of the nameplate word is upwards. 3.5 Assemble the MAIN CONTOL SYSTEM (see IPL1) 3.5.1 Install the CLAMP HOLDER (IPL1-150) 1) Assemble five PTFE RUBBER GROMMETS (IPL1-160) onto a CLAMP HOLDER (IPL1-150). 2) Place two damping cushions (IPL1-170) under each CLAMP HOLDER (IPL1-150). 3) From the back of the BACK PLATE (IPL1-20), install each CLAMP HOLDER (IPL1-150) steady to the BACK PLATE (IPL1-20) with four SCREWS (IPL1-120) which has set a WASHER (IPL1-130). After insuring the CLAMP HOLDER (IPL1-150) is shorting to the BACK PLATE (IPL1-20)turn the screws tightly with torque 1~2 NM. 4) Apply some LOCTITE 242 to the sect thread that outcrops above the nut, for all the screws. 3.5.2 Assemble the FAUCET VALVE ASSY SV1 (IPL1-190) 1) Wind previous 3 and 4 PTFE thread seal tape to the thread of an INLET FITTING (IPL1-200) and an OUTLET ELBOW (IPL1-230), according to direction of thread C.W. 2) Place a stainless steel filter into the inlet of the FAUCET VALVE ASSY (IPL1-190).And the filter dimension is like the inlet. 3) Fix the INLET FITTING (IPL1-200) and OUTLET ELBOW (IPL1-230) into the FAUCET VALVE ASSY SV1 (IPL1-190) and turn them tightly with torque 1~2 NM. Note: Promise the outlet direction of the OUTLET ELBOW (IPL1-230) is outwards the BACK PLATE (IPL1-20). 4) Set the serial number tube TB2-3 onto the end of one lead, and TB2-4 to another. Connect each end into a connect PATCH (IPL1-195). And insulate the end commendably with pyrocondensationin insulating sleeve. 5) Place a WASHER (IPL1-220) to each M5 round head SCREW (IPL1-210).From the back of the BACK PLATE (IPL1-20), installs the FAUCET VALVE ASSY SV1 (IPL1-190) steady to the BACK PLATE (IPL1-20) with two SCREWS (IPL1-210). And turn the

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screws tightly with torque 1~2 NM. 6) Place an ALUMINIUM BLOCK (IPL1-240) under the OUTLET ELBOW (IPL1-230). Apply little LOCTITE 242 to the top threads of two M3 SCREWS (IPL1-250), and place a WASHER (IPL1-260) to each screw. Though the install holes of the BACK PLATE (IPL1-20)and the ALUMINIUM BLOCK(IPL1-240),screw the two SCREWS (IPL1-210) into the OUTLET ELBOW(IPL1-230) to make it steady, and the torque is 1~1.5 NM. 3.5.3 Install the ELECTRONICS BOX ASSY (IPL1-270) 1) Place four DAMPING CUSHION(IPL1-110) under The ELECTRONICS BOX ASSY (IPL1-270).Place a WASHER(IPL1-130) to each of four SCREWS(IPL1-280),get though the hole of each DAMPING CUSHION(IPL1-110) and the install hole of the ELECTRONICS BOX ASSY(IPL1-270)from the back of the BACK PLATE (IPL1-20).And then place another WASHER(IPL1-130) and a SPRING WASHER(IPL1-300)to each SCREW (IPL1-280). 2) Apply little LOCTITE 242 to the top threads of EACH SCREWS(IPL1-280), then fix on a NUT(IPL1-290) to each SCREW(IPL1-280), After insuring the BOX cover is shorting to the BACK PLATE (IPL1-20), turn each screw tightly with torque 1~2 NM. 3.5.4 Fix the INLET ELBOW (IPL1-60) and OUTLETFITTING (IPL1-70) 1) Wind previous 3 and 4 PTFE thread seal tape to the thread of an INLET ELBOW (IPL1-60) And a OUTLETFITTING (IPL1-70), according to direction of thread C.W. 2) Fix the INLET ELBOW(IPL1-60) And the OUTLETFITTING(IPL1-70) to the inlet and the outlet of the PUMP ASSYIPL1-90with torque 2~3NM. Note: Make sure the inlet of the INLET ELBOW(IPL1-60) is outwards the underside of the PUMP ASSYIPL1-90 3) Set 6 length 3 pyrocondensationin insulating sleeve over the white lead(with serial number tube TB2-5), Shell the end 6 length, after puckering symmetrically, put the folio end into the connection hole of CONNECT PATCH (IPL4-140), tighten the connection hole, and weld them with little solder, then Insulate the joint commendably with pyrocondensationin insulating sleeve. Set the serial number tube to the joint end, with letter t toward the CONNECT PATCH. 4) According to the step 3),connect the orange lead with serial number tube TB2-6 black leadwith serial number tube TB2-7and red leadwith serial number tube TB2-8. 5) Cut short the green lead, and fold back into the sleeve of the cable, then Insulate it with pyrocondensationin insulating sleeve. 6) According to the step 3.1.15, Affix NAMEPLATE (IPL7-50) onto the back of the PUMP ASSY (IPL1-90), and make sure the direction of the nameplate word is upwards. 3.5.5 Install the PUMP ASSY (IPL1-90) 1) Place four DAMPING CUSHION(IPL1-110) under the PUMP ASSYIPL1-90. 2) Place a WASHER(IPL1-130) to each of four SCREWS(IPL1-280),get though the hole of each DAMPING CUSHION(IPL1-110) and the install hole of the PUMP ASSY IPL1-90 from the back of the BACK PLATE (IPL1-20).And then place another WASHER (IPL1-130) and a SPRING WASHER (IPL1-300) to each SCREW (IPL1-280).

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3) Apply some LOCTITE 242 to the top threads of EACH SCREWS(IPL1-280), then fix on a NUT(IPL1-290) to each SCREW(IPL1-280), After insuring the PUMP shell is shorting to the BACK PLATE (IPL1-20), turn tightly with torque 1~2 NM. 3.5.6 Install The WATER HEATER ASSY (IPL1-140) 1) Open the two CLAMP HOLDERS (IPL1-150), and install in the WATER HEATER ASSY (IPL1-140).And set a stainless steel shield underlay around the holder and near its locking nut, insure the WATER HEATER ASSY is shorting to the BACK PLATE (IPL1-20) after closing the holders. Notice:1.Should promise that the WATER LEVEL SWITCH IPL4-40direct to the FAUCET VALVE ASSY (IPL1-190). 2. Make sure the inlet and outlet of the WATER HEATER ASSY (IPL1-140) near to the BACK PLATE (IPL1-20). 3.5.7 Assemble the WATERPIPE (IPL1-50) of the Water Tank 1) Put a NUT(IPL1-40) inverse of the WATERPIPEIPL1-50onto one end of the WATERPIPEIPL1-50. Then draw the end onto the inlet of the FITTING (IPL1-30) tightly. Place on the Nut (IPL1-40); and turn tightly with less than 1NM torque. 2) Put another NUT(IPL1-40) inverse of the WATERPIPE IPL1-50 onto the other end of the WATERPIPEIPL1-50. Then draw the end onto the inlet of the INLET ELBOW (IPL1-60) tightly. Place on the Nut (IPL1-40); and turn tightly with less than 1 NM torque. 3.5.8 Assemble the WATERPIPE (IPL1-80) According to the step 3.5.7 methods, draw one end of a proper WATERPIPE (IPL1-80) to the outlet of the OUTLETFITTING (IPL1-70), and another end to the inlet of the WATER HEATER ASSY (IPL1-140) 3.5.9 Assemble the WATERPIPE (IPL1-180) According to the step 3.5.7 methods, draw one end of a proper WATERPIPE (IPL1-180) to the outlet of the WATER HEATER ASSY (IPL1-140), and another end to the inlet of the FAUCET VALVE ASSY (IPL1-190). 3.5.10 Hold the WATER HEATER ASSY (IPL1-140) Tightly 1) Screw the two CLAMP HOLDER (IPL1-150) to hold the WATER HEATER ASSY (IPL1-140) tightly with torque 2~3 NM. WARNING:SPECIAL PROMISE, THE INLET OF THE WATER HEATER ASSY (IPL1-140) IS HIGHER THAN THE OUTLET OF THE PUMP ASSYIPL1-90,AND THE OUTLET OF THE WATER HEATER ASSY (IPL1-140) IS LOWER THAN INLET OF THE FAUCET VALVE ASSY (IPL1-190). 2) Airproof the lead outlet near the flange of the COMPONENT HT1 (IPL4-30) finely with white silicone rubber. 3.5.11 Assemble the CABLE (IPL1-315) and the CONNECTOR P7 (IPL1-310)

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1) Connect the red lead of the CABLE (IPL1-315) to the second foot of the CONNECTOR P7 (IPL1-310); and the blue lead into the sixth foot. 2) According to methods of the step 3.2.2.2A, connect each end into a connect PATCH(IPL1-195). 3.5.12 Connect the Cables 1) Connect the connector P1(IPL4-90) of the TEMPERATURE SENSOR SNS1(IPL4-70) to the RECEPTACLE J1 IPL5-20 of the ELECTRONICS BOX ASSY IPL1-270 . 2) Ring the TB2-12(IPL5-60) with the TB2 SEAL GASKET (IPL5-280). 3)Connect the connect patch of the WATER LEVEL SWITCH FS1(IPL4-40) to the first and second feet of the TB2(IPL5-60) of the ELECTRONICS BOX ASSY IPL1-270 according to the serial number. 4) Connect the connect patch of the FAUCET VALVE ASSY SV1 (IPL1-190) to the third and fourth feet of the TB2 (IPL5-60) according to the serial number. 5) Connect the four connect patch of the PUMP ASSY (IPL1-90) to the 5th, 6th, 7th and 8th feet of the TB2 (IPL5-60) according to the serial number. 6) Connect the connect patch of the heating COMPONENT HT1 (IPL4-30) TB2-9, TB2-10 to the ninth and tenth feet of the TB2 (IPL5-60) according to the serial number. 7) Connect the TB2-11 connect patch of the CABLE (IPL1-315) with the P7 (IPL1-310) to event foot of the TB2 (IPL5-60), and the TB2-12 connect patch to twelfth foot. 3.5.13 Assemble the Protect Cover 1Sleeve the fixing screws of the TERMINAL BOARD ASSY TB1-2 (IPL5-50) with the COLUMN INSULATOR THIMBLE(IPL5-270) respectively. Fit on the TB1 PROTECT COVER (IPL5-110), and then respectively mount one WASHER (IPL5-200) and one M3 SELF-LOCK NUT (IPL5-190) in turn. 2) Fit the TB2 PROTECT COVER (IPL5-100) on the TERMINAL BOARD ASSY TB2-12 (IPL5-60) with its notch downwards, and the fixing screws through its fitting hole, and insure each notch locks the lead end respectively. Then respectively mount one WASHER (IPL5-200) on the fixing screws, after daubing some LOCTITE 242 on the thread, turn one M3 SELF-LOCK NUT (IPL5-190) on tightly with torque 1~1.5 NM. 3.5.13 Affix the NAMEPLATE (IPL1-340,360) 1) According to the step 3.1.15, affix NAMEPLATE(IPL1-340) onto the upside of the FAUCET VALVE ASSYIPL1-190and make sure the direction of the nameplate word is outwards the BACK PLATE (IPL1-20) . 2) According to the step 3.1.15, affix NAMEPLATE (IPL1-360) onto the underside middle of t the BACK PLATE (IPL1-20) and make sure the direction of the nameplate word is upwards. 3.5.14 Affix the DAMPING CUSHION (IPL1-330) 1) Clean surface near the install hole of the BACK PLATE (IPL1-20)and four DAMPING CUSHION(IPL1-330). 2) Smear the 0.1~0.2 thick film of white silicone rubber evenly onto the DAMPING CUSHION(IPL1-330).

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3) Affix the four DAMPING CUSHION (IPL1-330) s onto the back of the BACK PLATE (IPL1-20). Note: 1.Should promise the install hole of the BACK PLATE (IPL1-20) aligns to the hole of the DAMPING CUSHION (IPL1-330); 2. Should promise the outside of the DAMPING CUSHION (IPL1-330) is parallel to the outside near the install hole of the BACK PLATE (IPL1-20) 4 Store Elucidations 4.1 Pack a water system assembly hermetically. 4.2 Use a wood box or other according to profession etc. of the packing effect request, pack the system, in order to prevent it to be damage on the transport way. Mark the part number and serial number. 4.3 Storage the system according to the sail material standard request.

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FITS AND CLEARANCES 1Dimension Table 8001. Dimension TOLERANCE ITEM 1 2 3 NOMENCLATURE Cable Length of DRAIN VALVE ASSY BASIC TOLERANCE DIMENSION 500 10 10 10 2

Water Pipe Length From The Installation 330 Plane of The FAUCET ASSY Cable Length From The Installation Plane of 400 The Faucet Assy The Distance From The Screw Top of BEANPOLE IPL4-44 To Installation Base 15 of The Water Level Switch

2Torque:

Table 8002. Torque IPL ITEM IPL1-40 IPL1-60 IPL1-70 IPL1-120 IPL1-150 IPL1-200 IPL1-210 IPL1-230 IPL1-250 IPL1-280 IPL2-20 IPL2-60 IPL2-90 IPL2-100 IPL2-120 IPL2-120 IPL4-30 IPL4-70 IPL4-110 IPL5-203040 NOMENCLATURE M121 ELBOW,900 ,INLET FITTING,OUTLET SCREWM4 NUT OF CLAMP HOLDER FITTING,INLET SCREWM5,SELF-TAPING ELBOW,900, OUTLET SCREWM3, SCREWM4,ROUND HEAD COPING, FAUCET ASSY SCREW CAPFOR NOZZLE FITTINGIN FAUCET ASSY NUT M121 NUT, BUTTON PB1PB2 FIXING SCREW,BUTTON PB1PB2 COMPONENT HT1HEATER TEMPERATURE SENSOR SYSTEM,SNS1 NUT,M3,LOCKING NUT OF RECEPTACLE J1J2J3 TORQUENM 11.5 23 23 12 23 12 12 12 11.5 12 23 12 12 1 12 0.51 67 23 11.5 12

38-20-00

PAGE 801 MAY 18/08

IPL5-7080 IPL5-90 IPL5-160 IPL5-180 IPL5-220 IPL5-260 IPL2A-20 IPL2A-60 IPL2A-80

NUT OF SWITCH SW1SW2 NUT OF LAMP HOLDER DS1DS2 BOLT NUTM3 SCREWM3 NUT OF SWITCH SW201 NUTBUTTON NUTM121 SCREWM3,

12 12 11.5 11.5 11.5 12 23 12 12

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PAGE 802 MAY 18/08

SPECIAL TOOLS,FIXTURES AND EQUIPMENT 1Special Tools,Fixtures and Equipment The system has no special fixtures and equipment;but has two special tools as following: TABLE 9001. SPECIAL TOOLS SPECIAL TOOLS FAUCET SPECIAL TOOL WRENCH FOR VALVE COPING DRAIN TYPE HC3801-GJ-LT-01 HC3801-GJ-WS-01 SOURCE Hosun(Chengdu) Aviation Technology Co.,Ltd Hosun(Chengdu) Aviation Technology Co.,Ltd

FIG 9001. FAUCET SPECIAL TOOL

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PAGE 901 MAY 18/2008

FIG 9002. WRENCH FOR DRAIN VALVE COPING

38-20-00

PAGE 902 MAY 18/2008

ILLUSTRATED PARTS LIST 1Purpose The Illustrated Parts List is intended for use in identification and requisition of replaceable part and assemblies for the Water System Kit. 2Explanation and Usage of Section AIf the part number is not known 1Find the part in the exploded-view illustration. 2Note the item number assigned to the part. 3Refer to the parts list and find the item number in the FIG.ITEM column. BIf the part number is known 1Refer to the parts list or numerical index and find the part in the PART NUMBER column. 2Note the figure number and the item number assigned to the part in the FIG.ITEM column. 3Refer to the illustration to identify attaching hardware and related assembly parts.

38-20-00

PAGE 1001
MAY 18/2008

22 0 2 10

28 0

25 0

2 60

20

10

270

13 0

3 00

290

3 20

310

1 80

20 0

34 0

190

240

230

3 70

FAUCET ASSY
P3

28Vdc
1
2

J3

120

J2

P1

J1
11 12 11 10 9 8 7 6 5 4 3 2 1 TB2
()

12

8 7 6 5

1 1 5V a c

40

4 3 2 1

130

10

110 195 360 330 90 70 40 80

60

50

30

DRAIN VALVE ASSY

P2

140 380 170 15 0 1 60

IPL Figure 1. SYSTEM ASSEMBLY

38-20-00

PAGE 1002
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

1-10 1-20 1-30 1-40 1-50 1-60 1-70 1-80 1-90 1-110 1-120 1-130 1-140 1-150 1-160 1-170 1-180 1-190 1-195 1-200 1-210 1-220 1-230 1-240 1-250 1-260 1-270 1-280 1-290 1-300

HC3801-ZHK-01 HC3801-AZB-01 HC3801-JT-SX SJLM-M121 SG/PTFE-X-B HC3801-JT-SBJ HC3801-JT-SBC SG/PTFE-B-G HC3801-SB-0.3MPa JZD-12204 YTLD-M412 PD-M4 HC3801-JFG-2L JRGZJ-110-M4 KGD-121.5-60 JZD-12404 SG/PTFE-G-F HC3801-DF-RSC2 HC-360.5-1 HC3801-JT-FSFJ YTZGLD-M58 PD-M5 HC3801-JT-FSFC D-CS-16149 YTLD-M315 PD-M3 HC3801-KH-01 YTLD-M414 LM-M4 TD-M4

MAIN CONTROL SYSTEM ASSY BACK PLATE FITTING, TO WATER BANK NUT WATER PIPE ELBOW,900 ,INLET FITTING,OUTLET WATER PIPE PUMP ASSY

1 1 1 8 1 1 1 1 1

DAMPING CUSHION PUMP AND 8 ELECTRONICS BOX SCREWM4 , ROUND HEAD WASHER#4 WATER HEATER ASSY CLAMP HOLDERHEATER GROMMETPTFE RUBBER DAMPING CUSHIONHEATER WATER PIPE FAUCET VALVE ASSY SV1 PATCH CONNECT FITTING,INLET SCREWM5, ROUND HEAD WASHER#5 ELBOW,900, OUTLET BLOCKALUMINIUM SCREWM3, ROUND HEAD WASHER#3 ELECTRONICS BOX ASSY SCREWM4, ROUND HEAD NUTM4 SPRING WASHER#4 8 20 1 2 10 4 1 1 2 1 2 2 1 1 2 2 1 8 8 8

38-20-00

PAGE 1003
MAY 18/2008

1-310 1-315 1-320 1-330 1-340 1-360 1-370 1-370A 1-380

MS24266R14B07PN DL/PTFE-115-2300 MS27291-3 JZD-20204 HC3801-MP-FS-2# HC3801-MP-XT-2# HC3801-LT-01 HC3801-LT-01A HC3801-WS-24V

CONNECTORP7 CABLE115VAC BACK SHELL DAMPING SYSTEM CUSHION CONTROL

1 1 1 4 1 1 1(CHOO
SE)

NAMEPLATEFAUCET VALVE ASSY NAMEPLATESYSTEM FAUCET ASSY FAUCET ASSY DRAIN VALVE ASSY

1(CHOO
SE)

38-20-00

PAGE 1004
MAY 18/2008

10

30

20 120

40 70 80 12 0 50 60 90 13 0 14 0 1 00

1 10 10 0 21 0 1 80 170 1 50 1 60 19 0

IPL Figure 2. FAUCET ASSEMBLY

38-20-00

PAGE 1005
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

2-10 2-20 2-30 2-40 2-50 2-60 2-70 2-80 2-90 2-100 2-110 2-120 2-130 2-140 2-150 2-160 2-170 2-180 2-190 2-210

HC3801-LT-01 LT-DG-01 LT-Z-01 LT-CSTZ-01 LT-PZ-01 LT-CSTG-01 LT-CSZJ-01 LT-CSZJ-02 HC3801-JT-LTJ SJLM-M121 SG/PTFE-F-L HC3801-LT-01-10 HC3801-LT/WU-KGZ-W01 HC3801-LT/WU-KGZ-N02 DL/PTFE-LT-15004 FX9-4T PD-M5 SJLM-M5 HC3801-MP-LT-2# MD70502

FAUCET ASSY COPING HOUSING, FAUCET BACKBONEfor SPRAY MOUTH SPRAY MOUTH SCREW CAPfor SPRAY MOUTH SUPPORT INSIDE SUPPORT OUTSIDE FITTINGINNER NUTM121 WATER PIPE BUTTONPB1PB2 OUTSIDE SUPPORTPB2 INSIDE SUPPORTPB2 CABLE CONNECTORP3 WASHER 516 NUTM5 LOCK NAMEPLATEFAUCET ASSY GASKETHOUSING

1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 2 2 1 1

38-20-00

PAGE 1006
MAY 18/2008

10

60 30 70 40

20

100

80

90

50

IPL Figure 3. DRAIN VALVE ASSEMBLY

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

3-10 3-20 3-30 3-40 3-50 3-60 3-70 3-80 3-90 3-100

HC3801-WS-24V HC3801-WS-KLD20K WS-SJT-60-38 WS-AZLM-M36-DN15 WS-XJT-DN15-M272 WS-SL-320.5 WS-MFD-5545 DL/PTFE-LT-14003 FX9-3T HC3801-MP-WS-2#

DRAIN VALVE ASSY MOMENTVALVESV2 FITTINGUPSIDE ADAPTERDRAIN FITTINGUNDERSIDE SCREEN GASKET CABLE CONNECTORP2 NAMEPLATEDRAIN VALVE ASSY

1 1 1 1 1 1 1 1 1 1

38-20-00

PAGE 1007
MAY 18/2008

IPL Figure 4. WATER HEATER ASSEMBLY

38-20-00

PAGE 1008
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

4-10 4-20 4-30 4-40 4-42 4-44 4-46 4-48 4-50 4-60 4-65 4-70 4-90 4-100 4-110 4-120 4-130 4-140 4-150 4-160 4-170

HC3801-JRG-2L JRG-2L-GT-01 HC3801-JR-HRS0.5KW HC3801-SW-30.1 SW-30.1-FZ SW-30.1-ZG SW-30.1-KZ-90.5 SW-30.1-LM-M10 PTFE-10183 FL-SW-R1-1/4-35 GXJD-39.5483 HC3801-WD-AD592 FX9-2T JUC-079FA/505-B ZSLM-M3 DL/PTFE-JR-2250 PTFE-3720 HC-360.5-1 HC-D328F-R32311.5-3 PD-M3 HC3801-MP-JRG-2#

WATER HEATER ASSY WATER TANKHEATER COMPONENT HT1HEATER SWITCH FS1 WATER LEVEL FLOATER BEANPOLE CLIP NUT GASKETFS1 TRANSITION FITTINGFS1 GASKETFS1 TEMPERATURE SYSTEM,SNS1 CONNECTOR P1SNS1 TEMPERATURE PROTECTOR TS1 NUT,M3,LOCKING CABLE INSULATOR THIMBLECOLUMN PATCH CONNECT COVERPROTECT WASHER#3 NAMEPLATEWATER HEATER ASSY SENSOR

1 1 1 1 1 1 1 1 F 1 1 1 1 1 2 1 2 2 1 2 1

38-20-00

PAGE 1009
MAY 18/2008

IPL Figure 5. ELECTRONICS BOX ASSEMBLY

38-20-00

PAGE 1010
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

55-10 5-20 5-30 5-40 5-50 5-60 5-70 5-80 5-90 5-100 5-110 5-120 5-130 5-140 5-150 5-160 5-170 5-180 5-190 5-200 5-210 5-220 5-230 5-240 5-250 5-260

HC3801-KH-01 HC3801-KHB-01 FX9-2Z FX9-3Z FX9-4Z DT-45-A02W-02 DT-25-A02W-12 KN6A-202M KN6A-202M DH10-5-TF

ELECTRONICS BOX ASSY PCB ASSY RECEPTACLE J2DRAIN VALVE ASSY RECEPTACLE J3FAUCET ASSY

1 1 1 1

RECEPTACLE J1 TEMPERATURE SENSOR 1

TERMINAL BOARD ASSY TB1-228VDC 1 POWER SOURCE TERMINAL BOARD ASSY TB2-12 SWITCH SW128VDC POWER SOURCE SWITCH SW2 DISCHARGE LAMP HOLDER DS1DS2LED 1 1 1 2 1 1 1 1 1 3 8 4 7 4 8 11 12 1 1 1 1

HC3801-HG-113.52010 PROTECT COVER TB2 HC3801-HG-3816.51.5 PROTECT COVER TB1 HC3801-KHK-01 HC3801-KHK-02 HC3801-KHK-03 CTLD-M315 M36-HEX6 YTLD-M330 LM-M3 SJLM-M3 PD-M3 TD-M3 CTLD-M36 HC3801-MP-KH-2# 5Y3EUC 5R3EUC KN1A-202M COVERUPSIDE COVERUNDERSIDE COVER SIDE SCREWM3, FLAT HEAD BOLT SCREWM3, ROUND HEAD NUTM3 M3 NUTSELF-LOCK WASHER3 SPING WASHER3 SCREWM3, FLAT HEAD NAMEPLATE, ELECTRONICS BOX ASSY LED,DS1 LED,DS202 SWITCH SW201,115VPOWER SOURCE

38-20-00

PAGE 1011
MAY 18/2008

5-270 5-280 5-290 5-300

ZT-3710 HC3801-05-51 DE9P DA15P

INSULATOR THIMBLECOLUMN TB2 SEAL GASKET CONNECTOR P1,9 PIN CONNECTOR P2,15 PIN

2 1 1 1

38-20-00

PAGE 1012
MAY 18/2008

IPL Figure 6: PCB1of2

38-20-00

PAGE 1013
MAY 18/2008

IPL Figure 6: PCB2of2

38-20-00

PAGE 1014
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

6 6-10 6-20 6-30 6-40 6-50 6-60 6-70 6-80 6-90 6-100 6-105 6-110 6-120 6-130 6-140 6-150 6-160 6-170 6-180 6-190 6-200 6-210 6-220 6-230 6-240 6-250 6-260

HC3801-KHB-01 HC3801-01B DE9SZS DA15SZS 47uF/63V JCT41-0805B103K100N 470uF/16V 0805CQ270J250S JCT41-1206B104K100N 100uF/25V JCT41-0805B104K100N JCT41-0805B105K100N DT-25-B01W-05 DAP1-6A(400hz) DADP2-6A() WRB2415CSD HER505P 1N4007 1N4744A 251-005 JQX-113M JAN2N2222A IRF2807F 0 RII-15-0805-513J LR2512-1-0R025 RII-15-1206-103J RII-15-0805-101J

PCB ASSY PCB RECEPTACLE J1 RECEPTACLE J2 CAPACITOR C1, TANTALUM CAPACITOR ,C14 CAPACITOR , C6C17TANTALUM CAPACITOR ,C18C19 CAPACITOR ,C2C5C7 CAPACITOR,C4TANTALUM CAPACITOR,C8C13C20C23 CAPACITOR ,C16 TERMINAL BOARD ASSY ,CN202 FILTER,CT201 FILTER,CT1 POWER MODULE,U101 DIODE,D1 DIODE,D202D3,D5 DIODE,D4 FUSE,F1F201 RELAY,K201 AUDION Q1, NPN MOS,Q2 RESISTANCE,R100 RESISTANCE,R12 RESISTANCE,R13 RESISTANCE,R14 RESISTANCE,R2

1 1 1 1 1 1 2 2 3 1 10 1 1 1 1 1 1 3 1 2 1 1 1 DELETE 1 1 1 1

38-20-00

PAGE 1015
MAY 18/2008

6-270 6-280 6-290 6-300 6-310 6-320 6-330 6-340 6-350 6-360 6-370 6-380 6-390 6-400 6-410 6-420 6-430 6-440 6-450 6-460 6-470 6-480 6-490 6-500 6-510 6-520 6-530 6-540

EE1/10-6.2K-BC5 30K/1W-1% *100270/0.25W-1%

RESISTANCE,R201 RESISTANCE,RDS201 RESISTANCE,R202

1 1 1 collocating 1 collocating 1 1

* 3.3K3.9K/0.25W-1% RESISTANCE,R203 EE1/10-12.7K-BC5 1K/0.25W RII-15-0805-512J RII-15-0805-153J RII-15-0805-332J RII-15-0805-102J 3.0K/0.125W 30K/0.125W V39ZA6P 14K181 1.5KE33A SMBJ5.0A SMBJ5CA SMBJ33CA P6KE33CA LM140LAH-5.0/883 LF111H/883 HC3801-CPU-PF ADM810MART SNJ54HC14J LT1910ES8 IPS511G AD581JH 4SMX-12.0MHZ RESISTANCE,R205 RESISTANCE,R26

RESISTANCE,R3R9R10R11R15R18 7 R21 RESISTANCE,R4R6R16R17R19R20 8 R22R23 RESISTANCER5R7 RESISTANCER8 RESISTANCER24 RESISTANCER25 RESISTANCE RV1VOLTAGE SENSITIVITY RESISTANCE RV2VOLTAGE SENSITIVITY
ZENER DIODE ,TVS1

2 1 1 1 1 DELETE 1 1 1 3 1 1 1 1 1 1 3 1 1

ZENER DIODE ,TVS2 ZENER DIODE,TVS6 ZENER DIODE, TVS7TVS8TVS9 REGULATOR N., U1 COMPARINGU10 CPUU2(WITH SETING) REVERSERU3 INVERTERU4 TRIGGERU5 TRIGGERU6U7,U8 REGULATOR N.U9 OSCILLATORY1

DIODE TVS3 TVS4 TVS5 INSTANT RESTRAIN 3

38-20-00

PAGE 1016
MAY 18/2008

40
8

50

7 6 5

30

20

IPL Figure 7: PUMP ASSEMBLY

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

7-10 7-20 7-30 7-40 7-50

HC3801-SB-0.3MPa L24557 DL-SB-11203 HC-360.5-1 HC3801-MP-SB-2#

PUMP ASSY PUMP CABLE PATCH CONNECT NAMEPLATE, PUMP ASSY

1 1 1 4 1

38-20-00

PAGE 1017
MAY 18/2008

IPL 2A.

38-20-00

1001A MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

2A2A-10 2A-20 2A-30 2A-40 2A-50 2A-60 2A-70 2A-80 2A-90 2A-100 2A-110 2A-120 2A-130 2A-140

HC3801-LT-01A LT-Z-01A HC3801-LT-01-10 LT-LS-01A LT-CSTZ-01A LT-CST-01A SJLM-M121 SG/PTFE-F-L CTLD-M36 MD9462 15121.2 20160.3 DL/PTFE-LT-15004 FX9-4T HC3801-MP-LT-2#

FAUCET ASSY HOUSING, FAUCET BUTTONPB1PB2 BOLT,INSTALL BACKBONEfor SPRAY MOUTH SPRAY MOUTH NUTM121 WATER PIPE SCREW GASKETHOUSING SEAL GASKET DECORATIVE GASKET CABLE CONNECTORP3 NAMEPLATEFAUCET ASSY

1 1 2 2 1 1 2 1 1 1 1 1 1 1 1

38-20-00

PAGE 1002A
MAY 18/2008

ILLUSTRATED PARTS LIST 1Purpose The Illustrated Parts List is intended for use in identification and requisition of replaceable part and assemblies for the Water System Kit. 2Explanation and Usage of Section AIf the part number is not known 1Find the part in the exploded-view illustration. 2Note the item number assigned to the part. 3Refer to the parts list and find the item number in the FIG.ITEM column. BIf the part number is known 1Refer to the parts list or numerical index and find the part in the PART NUMBER column. 2Note the figure number and the item number assigned to the part in the FIG.ITEM column. 3Refer to the illustration to identify attaching hardware and related assembly parts.

38-20-00

PAGE 1001
MAY 18/2008

22 0 2 10

28 0

25 0

2 60

20

10

270

13 0

3 00

290

3 20

310

1 80

20 0

34 0

190

240

230

3 70

FAUCET ASSY
P3

28Vdc
1
2

J3

120

J2

P1

J1
11 12 11 10 9 8 7 6 5 4 3 2 1 TB2
()

12

8 7 6 5

1 1 5V a c

40

4 3 2 1

130

10

110 195 360 330 90 70 40 80

60

50

30

DRAIN VALVE ASSY

P2

140 380 170 15 0 1 60

IPL Figure 1. SYSTEM ASSEMBLY

38-20-00

PAGE 1002
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

1-10 1-20 1-30 1-40 1-50 1-60 1-70 1-80 1-90 1-110 1-120 1-130 1-140 1-150 1-160 1-170 1-180 1-190 1-195 1-200 1-210 1-220 1-230 1-240 1-250 1-260 1-270 1-280 1-290

HC3801-ZHK-01 HC3801-AZB-01 HC3801-JT-SX SJLM-M121 SG/PTFE-X-B HC3801-JT-SBJ HC3801-JT-SBC SG/PTFE-B-G HC3801-SB-0.3MPa JZD-12204 YTLD-M412 PD-M4 HC3801-JFG-2L JRGZJ-110-M4 KGD-121.5-60 JZD-12404 SG/PTFE-G-F HC3801-DF-RSC2 HC-360.5-1 HC3801-JT-FSFJ YTZGLD-M58 PD-M5 HC3801-JT-FSFC D-CS-16149 YTLD-M315 PD-M3 HC3801-KH-01 YTLD-M414 LM-M4

MAIN CONTROL SYSTEM ASSY BACK PLATE FITTING, TO WATER BANK NUT WATER PIPE ELBOW,900 ,INLET FITTING,OUTLET WATER PIPE PUMP ASSY

1 1 1 8 1 1 1 1 1

DAMPING CUSHION PUMP AND 8 ELECTRONICS BOX SCREWM4 , ROUND HEAD WASHER#4 WATER HEATER ASSY CLAMP HOLDERHEATER GROMMETPTFE RUBBER DAMPING CUSHIONHEATER WATER PIPE FAUCET VALVE ASSY SV1 PATCH CONNECT FITTING,INLET SCREWM5, ROUND HEAD WASHER#5 ELBOW,900, OUTLET BLOCKALUMINIUM SCREWM3, ROUND HEAD WASHER#3 ELECTRONICS BOX ASSY SCREWM4, ROUND HEAD NUTM4 8 20 1 2 10 4 1 1 2 1 2 2 1 1 2 2 1 8 8

38-20-00

PAGE 1003
MAY 18/2008

1-300 1-310 1-315 1-320 1-330 1-340 1-360 1-370 1-370A 1-380

TD-M4 MS24266R14B07PN DL/PTFE-115-2300 MS27291-3 JZD-20204 HC3801-MP-FS-2# HC3801-MP-XT-2# HC3801-LT-01 HC3801-LT-01A HC3801-WS-24V

SPRING WASHER#4 CONNECTORP7 CABLE115VAC BACK SHELL DAMPING SYSTEM CUSHION CONTROL

8 1 1 1 4 1 1 1(CHOO
SE)

NAMEPLATEFAUCET VALVE ASSY NAMEPLATESYSTEM FAUCET ASSY FAUCET ASSY DRAIN VALVE ASSY

1(CHOO
SE)

38-20-00

PAGE 1004
MAY 18/2008

10

30

20 120

40 70 80 12 0 50 60 90 13 0 14 0 1 00

1 10 10 0 21 0 1 80 170 1 50 1 60 19 0

IPL Figure 2. FAUCET ASSEMBLY

38-20-00

PAGE 1005
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

2-10 2-20 2-30 2-40 2-50 2-60 2-70 2-80 2-90 2-100 2-110 2-120 2-130 2-140 2-150 2-160 2-170 2-180 2-190 2-210

HC3801-LT-01 LT-DG-01 LT-Z-01 LT-CSTZ-01 LT-PZ-01 LT-CSTG-01 LT-CSZJ-01 LT-CSZJ-02 HC3801-JT-LTJ SJLM-M121 SG/PTFE-F-L HC3801-LT-01-10 HC3801-LT/WU-KGZ-W01 HC3801-LT/WU-KGZ-N02 DL/PTFE-LT-15004 FX9-4T PD-M5 SJLM-M5 HC3801-MP-LT-2# MD70502

FAUCET ASSY COPING HOUSING, FAUCET BACKBONEfor SPRAY MOUTH SPRAY MOUTH SCREW CAPfor SPRAY MOUTH SUPPORT INSIDE SUPPORT OUTSIDE FITTINGINNER NUTM121 WATER PIPE BUTTONPB1PB2 OUTSIDE SUPPORTPB2 INSIDE SUPPORTPB2 CABLE CONNECTORP3 WASHER 516 NUTM5 LOCK NAMEPLATEFAUCET ASSY GASKETHOUSING

1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 2 2 1 1

38-20-00

PAGE 1006
MAY 18/2008

10

60 30 70 40

20

100

80

90

50

IPL Figure 3. DRAIN VALVE ASSEMBLY

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

3-10 3-20 3-30 3-40 3-50 3-60 3-70 3-80 3-90 3-100

HC3801-WS-24V HC3801-WS-KLD20K WS-SJT-60-38 WS-AZLM-M36-DN15 WS-XJT-DN15-M272 WS-SL-320.5 WS-MFD-5545 DL/PTFE-LT-14003 FX9-3T HC3801-MP-WS-2#

DRAIN VALVE ASSY MOMENTVALVESV2 FITTINGUPSIDE ADAPTERDRAIN FITTINGUNDERSIDE SCREEN GASKET CABLE CONNECTORP2 NAMEPLATEDRAIN VALVE ASSY

1 1 1 1 1 1 1 1 1 1

38-20-00

PAGE 1007
MAY 18/2008

IPL Figure 4. WATER HEATER ASSEMBLY

FIG

PART

1 2 3 4 5 6 7 NOMENCLATURE

UNITS

38-20-00

PAGE 1008
MAY 18/2008

ITEM

NUMBER

PER ASSY

4-10 4-20 4-30 4-40 4-42 4-44 4-46 4-48 4-50 4-60 4-65 4-70 4-90 4-100 4-110 4-120 4-130 4-140 4-150 4-160 4-170

HC3801-JRG-2L JRG-2L-GT-01 HC3801-JR-HRS0.5KW HC3801-SW-30.1 SW-30.1-FZ SW-30.1-ZG SW-30.1-KZ-90.5 SW-30.1-LM-M10 PTFE-10183 FL-SW-R1-1/4-35 GXJD-39.5483 HC3801-WD-AD592 FX9-2T JUC-079FA/505-B ZSLM-M3 DL/PTFE-JR-2250 PTFE-3720 HC-360.5-1 HC-D328F-R32311.5-3 PD-M3 HC3801-MP-JRG-2#

WATER HEATER ASSY WATER TANKHEATER COMPONENT HT1HEATER SWITCH FS1 WATER LEVEL FLOATER BEANPOLE CLIP NUT GASKETFS1 TRANSITION FITTINGFS1 GASKETFS1 TEMPERATURE SYSTEM,SNS1 CONNECTOR P1SNS1 TEMPERATURE PROTECTOR TS1 NUT,M3,LOCKING CABLE INSULATOR THIMBLECOLUMN PATCH CONNECT COVERPROTECT WASHER#3 NAMEPLATEWATER HEATER ASSY SENSOR

1 1 1 1 1 1 1 1 F 1 1 1 1 1 2 1 2 2 1 2 1

38-20-00

PAGE 1009
MAY 18/2008

IPL Figure 5. ELECTRONICS BOX ASSEMBLY

38-20-00

PAGE 1010
MAY 18/2008

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

55-10 5-20 5-30 5-40 5-50 5-60 5-70 5-80 5-90 5-100 5-110 5-120 5-130 5-140 5-150 5-160 5-170 5-180 5-190 5-200 5-210 5-220 5-230 5-240 5-250 5-260 5-270

HC3801-KH-01 HC3801-KHB-01 FX9-2Z FX9-3Z FX9-4Z DT-45-A02W-02 DT-25-A02W-12 KN6A-202M KN6A-202M DH10-5-TF

ELECTRONICS BOX ASSY PCB ASSY RECEPTACLE J2DRAIN VALVE ASSY RECEPTACLE J3FAUCET ASSY

1 1 1 1

RECEPTACLE J1 TEMPERATURE SENSOR 1

TERMINAL BOARD ASSY TB1-228VDC 1 POWER SOURCE TERMINAL BOARD ASSY TB2-12 SWITCH SW128VDC POWER SOURCE SWITCH SW2 DISCHARGE LAMP HOLDER DS1DS2LED 1 1 1 2 1 1 1 1 1 3 8 4 7 4 8 11 12 1 1 1 1 2

HC3801-HG-113.52010 PROTECT COVER TB2 HC3801-HG-3816.51.5 PROTECT COVER TB1 HC3801-KHK-01 HC3801-KHK-02 HC3801-KHK-03 CTLD-M315 M36-HEX6 YTLD-M330 LM-M3 SJLM-M3 PD-M3 TD-M3 CTLD-M36 HC3801-MP-KH-2# 5Y3EUC 5R3EUC KN1A-202M ZT-3710 COVERUPSIDE COVERUNDERSIDE COVER SIDE SCREWM3, FLAT HEAD BOLT SCREWM3, ROUND HEAD NUTM3 M3 NUTSELF-LOCK WASHER3 SPING WASHER3 SCREWM3, FLAT HEAD NAMEPLATE, ELECTRONICS BOX ASSY LED,DS1 LED,DS202 SWITCH SW201,115VPOWER SOURCE INSULATOR THIMBLECOLUMN

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5-280 5-290 5-300

HC3801-05-51 DE9P DA15P

TB2 SEAL GASKET CONNECTOR P1,9 PIN CONNECTOR P2,15 PIN

1 1 1

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40
8

50

7 6 5

30

20

IPL Figure 7: PUMP ASSEMBLY

FIG ITEM

PART NUMBER

1 2 3 4 5 6 7 NOMENCLATURE

UNITS PER ASSY

7-10 7-20 7-30 7-40 7-50

HC3801-SB-0.3MPa L24557 DL-SB-11203 HC-360.5-1 HC3801-MP-SB-2#

PUMP ASSY PUMP CABLE PATCH CONNECT NAMEPLATE, PUMP ASSY

1 1 1 4 1

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PAGE 1014
MAY 18/2008