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Monogram Systems 1500 Glenn Curtiss, Carson, California 90746-4012
SERVICE AND MAINTENANCE MANUAL FOR EXECUTIVE AIRCRAFT TOILETS SERIES 4620 AND 12300
DISTRIBUTION STATEMENT This document contains proprietary information of Monogram Systems, and it is issued in strict confidence. Except for rights expressly granted by contract, this document may not, in whole or in part, be duplicated, reproduced, disclosed, or used for design or manufacturing purposes without written authorization from Monogram Systems.
MM4620
T-1 Jan 9/04
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
TO:
Holders of Service and Maintenance Manual No. 4620 AND 12300, dated January 9/04. REVISION NO. 1 DATED JANUARY 9/04 HIGHLIGHTS
Pages which have been revised or added are outlined below together with a summary of the revision. This is a PARTIAL revision. Please replace and discard affected pages and record in RECORD OF REVISIONS. Page Number
Description of Change
Title Page
Revised to reflect current revision.
Record of Revisions
Revised to reflect current revision.
List of Effective Pages
Revised to reflect current revision.
Intro-1 and Intro-3
Revised.
8, 9, 17, 22, 40, 41, 54, 58
Revised pages.
17.1, 17.2
Added pages.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
RECORD OF REVISIONS REV NO. 0 1
ISSUE DATE Dec 1/97 Jan 9/04
DATE INSERTED Dec 1/97 Jan 9/04
BY
REV NO.
ISSUE DATE
DATE INSERTED
BY
MS MS
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
LIST OF EFFECTIVE PAGES
SUBJECT Title Record of Revisions List of Effective Pages Table of Contents List of Figures Introduction
Description and Operation
Installation and Servicing
DATE
SUBJECT
T-1
Jan 9/04
RR-1
Jan 9/04
Testing and Fault Isolation
LEP-1 LEP-2
Jan 9/04 Jan 9/04
TC-1 TC-2
Dec 1/97 Dec 1/97
LOF-1
Dec 1/97
INTRO-1 INTRO-2 INTRO-3
Jan 9/04 Dec 1/97 Dec 1/97
1 2 3 4 5 6 7 8 9
Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Jan 9/04 Jan 9/04
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Dec 1/97 Dec 1/97 Dec 1/97 Jan 9/04 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97
Cleaning
34 35
Dec 1/97 Dec 1/97
Inspection
10 11 12 13 14 15 16 17 17.1 17.2 18
Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Jan 9/04 Jan 9/04 Jan 9/04 Dec 1/97
36 37 38 39 40 41 42
Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Jan 9/04 Dec 1/97
Disassembly
43 44 45 46 47 48 49
Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97
PAGE
PAGE
DATE
* The asterisk indicates pages changed, added or deleted F = Foldout Page
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
LIST OF EFFECTIVE PAGES
SUBJECT
PAGE
DATE
Repair
50 51 52
Dec 1/97 Dec 1/97 Dec 1/97
Assembly
53 54 55 56 57 58 59 60 61 62 63 64
Dec 1/97 Jan 9/04 Dec 1/97 Dec 1/97 Dec 1/97 Jan 9/04 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97 Dec 1/97
Illustrated Parts List
65
Dec 1/97
SUBJECT
PAGE
DATE
* The asterisk indicates pages changed, added or deleted F = Foldout Page
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
TABLE OF CONTENTS SUBJECT
PAGE
INTRODUCTION General Product Support Services Layout of Manual Abbreviations IPL4620 Series Manual Cross-Reference
INTRO-1 INTRO-1 INTRO-1 INTRO-1 INTRO-1 INTRO-2
DESCRIPTION AND OPERATION General Description Description of Components Operation Servicing Instructions Leading Particulars
1 1 1 3 4 4 8
INSTALLATION AND SERVICING General Assembly Options Installation Dimensions Installation Procedure
10 10 10 12 18
TESTING AND FAULT ISOLATION General Equipment and Materials Testing Procedures Fault Isolation
19 19 19 20 29
CLEANING General Equipment and Materials Cleaning Procedures
34 34 34 35
INSPECTION General Check Procedure
36 36 37
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
TABLE OF CONTENTS SUBJECT
PAGE
DISASSEMBLY General Equipment and Materials Disassembly Procedures
43 43 43 44
REPAIR General Equipment and Materials Repair Procedures
50 50 50 51
ASSEMBLY General Equipment and Materials Assembly Procedures
53 53 53 54
ILLUSTRATED PARTS LIST General
65 65
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
LIST OF FIGURES FIGURE
DESCRIPTION
PAGE
Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 11 Figure 11 Figure 11 Figure 12 Figure 13
Toilet Assembly (typical) Installation with Drain and Typical Options Installation Dimensions (Typical) Toilet Assembly Test Setup (Typical) Cartridge or Motor Pump Filter Assembly Test Setup (Typical) Toilet Timer Assembly Test Setup (Typical) LLT Test Harness Setup Toilet Wiring Diagrams Transmitter Schematic Diagram Gear Box Grease Application Clutch Mechanism Setting Drive Shaft and Impeller Adjustment Seal Lubrication Motor Shaft Alignment Boot Installation Mushroom Valve Installation
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2 11 13 21 23 26 28 39 42 57 58 59 59 61 61 63
Page LOF-1 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
INTRODUCTION 1.
General This publication contains shop maintenance instructions to maintain, troubleshoot and test the toilet assembly. The toilet assembly is manufactured by Monogram Systems.
2.
Product Support Services Contact Monogram Systems for repair services, technical documents, replacement parts, and other product support services. Monogram Systems 1500 Glenn Curtiss Carson, CA 90746-4012, USA Telephone: (310) 884-7000 Fax: (310) 884-7300 SITA: LAXMOXD
3.
Layout of Manual The information in this manual is divided into sections to enable maintenance personnel to disassemble, clean, repair, assemble, troubleshoot, and test the component. The applicable IPL4620 Series manual contains the illustrated parts list is to locate, identify, and requisition parts. Refer to Table I for toilet assembly part number to manual number cross-reference.
4.
Abbreviations Abbreviations used throughout this manual are defined as follows: ASSY FIG. GPM IPL LH NA No. PN
Assembly Figure Gallon Per Minute Illustrated Parts List Left Hand Not Applicable Number Part Number
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
5.
IPL4620 Series Manual Cross-Reference Table I provides a cross-reference of a 4620 Series or 12300 Series toilet assembly to its applicable IPL4620 Series manual.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
Toilet Assembly 4620-1 4620-2 4620-3 4620-3-13 4620-4 4620-6 4620-8 4620-8-1 4620-9 4620-9-1 4620-10 4620-10-1 4620-14 4620-16 4620-17 4620-21 4620-27 4620-31 4620-32 4620-34 4620-36 4620-37 4620-39 4620-40 4620-43 4620-44 4620-48 4620-50 4620-51 4620-53 4620-54 4620-55 4620-56 4620-57 4620-60
IPL4620 Manual IPL4620-1 IPL4620-1 IPL4620-1 IPL4620-1 IPL4620-2 IPL4620-3 IPL4620-3 IPL4620-3 IPL4620-4 IPL4620-4 IPL4620-4 IPL4620-4 IPL4620-5 IPL4620-6 IPL4620-2 IPL4620-1 IPL4620-3 IPL4620-1 IPL4620-1 IPL4620-1 IPL4620-1 IPL4620-3 IPL4620-2 IPL4620-8 IPL4620-9 IPL4620-9 IPL4620-10 IPL4620-11 IPL4620-8 IPL4620-11 IPL4620-12 IPL4620-9 IPL4620-2 IPL4620-9 IPL4620-9
Toilet Assembly 4620-65 4620-65-1 4620-66 4620-67 4620-68 4620-69 4620-70 4620-71 4620-73 4620-74 4620-76 4620-84 4620-85 4620-86 4620-87 4620-87-1 4620-90 4620-91 4620-92 4620-93 4620-94 4620-95 4620-96 4620-97 4620-98 4620-99 4620-100 4620-103 4620-104 4620-105 4620-106 4620-108 4620-108-1 12300
IPL4620 Manual IPL4620-9 IPL4620-9 IPL4620-9 IPL4620-9 IPL4620-2 IPL4620-2 IPL4620-13 IPL4620-13 IPL4620-14 IPL4620-7 IPL4620-7 IPL4620-9 IPL4620-10 IPL4620-3 IPL4620-3 IPL4620-3 IPL4620-9 IPL4620-14 IPL4620-8 IPL4620-7 IPL4620-2 IPL4620-9 IPL4620-9 IPL4620-9 IPL4620-9 IPL4620-8 IPL4620-3 IPL4620-3 IPL4620-8 IPL4620-9 IPL4620-2 IPL4620-3 IPL4620-3 IPL12300-1
Toilet Assembly to IPL4620 Series Manual Cross-Reference Table I
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
DESCRIPTION AND OPERATION 1.
General A.
2.
The toilet assembly described in this manual is part of the waste system designed to provide an aircraft sanitation system for in-flight and ground operations. The toilet collects waste products and uses recirculated flush water for rinsing the sides of the bowl. Waste material is collected and held in the toilet tank until serviced.
Description A.
The toilet mounts in a rigid aluminum frame (some models) which can be conveniently installed to suit a wide range of aircraft structures. The toilet unit clamps into the mounting frame by means of detachable holdown rods. See Figure 1. The complete toilet can be disconnected and lifted out of its mounting, or re-installed within a few minutes.
B.
All mating junctions of toilet tank and bowl are sealed. A perforated spray rinse fitting located in the top of the tank rinses the inside walls of the tank during ground servicing. (On models equipped with a fixed filter cartridge assemblies the tank is rinsed by the pump’s built-in rinse system). For ultimate sanitation and ease of maintenance, the entire toilet structure (except for motor and wiring) is constructed of heavy duty plastics, stainless steel and non-corrosive metals. The toilet bowl is constructed of highly polished stainless steel.
C.
The toilet may be serviced in either of two methods, depending upon the aircraft installation. On aircraft equipped with a sewage drain, the unit is mounted over the drain and is cleaned by opening the tank drain valve, which allows waste material to empty into the sewage drain. The inside of the tank is rinsed by connecting a water hose to the service panel on the exterior of the aircraft. In aircraft not equipped with a sewage drain, the toilet is serviced by removing the shroud, disconnecting the power input plug and toilet vent, and unclamping the unit after which the toilet can be carried out of the aircraft. Refer to Paragraph 5 for detailed servicing information.
D.
All toilet models may be used as a static chemical toilet by removing the restrictor or opening the separator at the bottom of the bowl.
E.
For further descriptive data, refer to the leading particulars for the applicable model toilet.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
Toilet Assembly (typical) Figure 1
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
3.
Description of Components A.
Timer and Mounting Bracket (some models) This unit includes the electrical power input connector and the timer, compactly mounted on a bracket which is secured to the top to the tank. All of the electrical wiring for the toilet is thus localized to one area of the toilet. The toilet flush button extends upward from the timer and is conveniently located beside the toilet seat. When the flush button is fully depressed, switch contacts within the timer are closed to energize the motor. The switch remains closed until the timer has completed its cycle of 9 seconds, after which the contacts open, disconnecting power to the motor section of the cartridge.
B.
Cartridge or Motor Pump Filter Assembly The cartridge (3500 Series and 4910 Series) consists of a motor, pump, and filter in one compact unit. The motor is mounted on the upper end of a gear train that drives both the filter and pump which extends into the tank. The filter is comprised of a plastic basket, the sides of which have multiple horizontal slotted openings and a solid bottom. The filter basket rotates at approximately 80 RPM. Two stationary plastic combs support the basket on opposite sides, with the teeth of the combs extending into the slotted openings in the basket. The motor pump filter assembly (3511, 3512 or 3519 Series) consists of motor, static teflon coated perforated filter, pump impeller, and rotating spray nozzle housing. Both the cartridge and motor pump filter assembly are designed as complete units and are easily removable for service and replacement.
C.
Drain Valve A spring-loaded, neoprene plunger is located in a valve seat in the bottom of the toilet tank. The valve is actuated by a cable terminating outside the toilet top area. In typical aircraft installations the cable is extended to a ground servicing panel or suitable location accessible from the exterior of the aircraft. In this arrangement the toilet waste contents can be emptied into the aircraft drain and all necessary servicing accomplished from outside the aircraft, quickly and efficiently.
D.
Liquid Level Transmitter The liquid level transmitter is a solid state electronic device capable of sensing two discrete points of fill on the toilet tank and transmitting an electronic signal for precharge level or full-tank level. The level sensors are located on an inside wall of the tank and the transmitter is mounted on the top of the tank.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
4.
Operation A.
5.
The flushing cycle is initiated by depressing and releasing a timer button adjacent to the toilet which actuates a motor-driven pump and filter for a pre-timed interval (approximately 9 ? 1 seconds). During the 9 second cycle, flushing liquid cascades in a thin curtain over the complete inner surface of the toilet bowl from a flush channel surrounding the upper rim of the bowl. Waste material is carried directly to the tank and prevented from re-entry by means of a restrictor or separator in the bottom of the bowl. Flushing liquid is filtered out of the tank through the self-cleaning rotary filter (or fixed filter) and is pumped up to the flush channel surrounding the toilet bowl. The motorpump and filter are designed as a single modular assembly. Some models are referred to as a cartridge, which can be quickly removed and replaced if overhaul or maintenance is required.
Servicing Instructions A.
Charging of Toilet (1)
The recommended initial charge of flushing liquid is a mixture of water and one packet (two ounces) of Monogram Monochem® Toilet Chemical. The required quantity of water for any toilet model should be enough for the cartridge or motor pump filter assembly to flush the toilet without starvation. NOTE:
(2)
The cartridge or motor pump filter assembly may be run dry (with no flushing fluid) without damage to the pump.
To protect the toilet recirculation system against freezing temperatures, add an automotive anti-freeze to the flushing liquid in the ratio recommended by the antifreeze manufacturer.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
B.
Aircraft without Sewage Drain (1)
Unclamp the toilet from mounting frame and disconnect electrical power and vent line from toilet (as applicable).
(2)
Lift the toilet from the aircraft and take it to the service area. Set the tank drain over a sewage pipe or regular toilet bowl.
(3)
Connect water hose to tank flush inlet fitting.
(4)
Pull cable of drain valve to dump waste from toilet.
(5)
Turn water supply on for approximately three minutes with tank valve open. Close drain valve and fill tank with approximately four gallons of water.
(6)
Turn water off and open drain valve to empty water from tank. Repeat flush-rinse cycle as necessary. NOTE:
Commercial detergents and disinfectants can be included in the rinse cycle if desired, however the final toilet charge should not include these materials.
(7)
Close valve and disconnect water hose from tank flush fitting.
(8)
If desired, toilet operation can be checked as follows: (a)
With the drain valve closed, fill tank with approximately two gallons of clear water through the bowl.
(b)
Connect electrical power (as applicable) to the toilet. See Figure 8 for applicable electrical requirement and connections.
(c)
Operate toilet for at least three complete flush cycles and observe flushing action. When the filter is free of foreign material, flushing should be vigorous and consistent with a curtain of water completely covering the inside of the bowl throughout the entire flush cycle.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
(9)
(d)
If flushing action is not satisfactory, refer to INSPECTION, Paragraph 2.C., Inspection and Cleaning of Filter.
(e)
Drain tank and clean toilet bowl with wet sponge and mild detergent.
Reinstall toilet in aircraft, connecting electrical power and vent line (as applicable).
(10) Charge the empty tank through the bowl with required amount of water and one packet (two ounces) of Monogram Monochem® as indicated in Paragraph A., Charging of Toilet.
C.
Aircraft with Sewage Service Panel (1)
Connect external sewage hose and tank flush hose to service panel.
(2)
Actuate cable to open toilet drain valve and dump waste into sewage line.
(3)
Turn flush water on and run water through service flush fitting for approximately three minutes with the drain valve open. Release cable to close drain valve and fill tank with approximately four gallons of water.
(4)
Turn water off and open drain valve to empty water from tank. Close the drain valve.
(5)
If desired, toilet operation can be checked as follows: (a)
Fill tank with approximately two gallons of clear water.
(b)
Operate toilet for at least three complete flush cycles and observe flushing action. When filter is free of foreign material, flushing should be vigorous and consistent with a curtain of water completely covering the inside of the bowl throughout the entire flush cycle.
(c)
If flushing action is not satisfactory, refer to INSPECTION, Paragraph 2.C., Inspection and Cleaning of Filter.
(d)
Drain tank and clean toilet bowl with wet sponge and mild disinfectant.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
(6)
Charge the empty tank through the bowl or through the service panel flush fitting with the required amount of water and one packet (two ounces) of Monogram Monochem® as indicated in Paragraph A., Charging of Toilet.
(7)
Disconnect sewage and water lines from the service panel.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
5.
Leading Particulars Refer to Table 1 for the leading particulars of the toilets covered by this manual.
Use .................................................................................................................Aircraft Toilet Facilities Electrical Power Requirement: PN 4620-1, -2, -3, -3-13, -21, -31, -32, -34, -36, 12300 .............................. 28 VDC 10 A max. PN 4620-4, -14, -17........................................................................................ 28 VDC 3 A max. PN 4620-6, -27, -37........................................................................................ 28 VDC 6 A max. PN 4620-39, -40, -43, -44, -48, -50, -51, -53, -54, -55, -56, -60,................... 28 VDC 4 A max. -65, -65-1, -66, -67, -68, -69, -70, -71, -73, -74, -76, -84, -85, -86, -87, -87-1, -90, -91, -92, -93, -94, -95, -96, -97, -98, -99, -100, -103, -104, -105, -106, -108, 108-1 PN 4620-8, -16......................................................... 115/200 VAC 400 Hz 3-phase 0.9 A max. PN 4620-8-1, -9, -9-1, -10, -10-1 ............................. 115/200 VAC 400 Hz 3-phase 0.8 A max. Electrical Connection: PN 4620-1, -2, -3, -3-13, -4, -6, -17, -21, -27, -31, .......................Receptacle MS3100E16S-4P -34, -36, -37, -40, -51, -54, -68, -69, -86, -87, 12300 PN 4620-8, -16..........................................................................Receptacle MS24266R14B7PN PN 4620-8-1, -9, -9-1, -10, -10-1 ............................................. Receptacle NAS1653R10B6PN PN 4620-14 .................................................................................Terminal Board MS24212-1-2 PN 4620-39, -56............................................................................ Receptacle MS3100F16S-4P PN 4620-43, -44, -55, -57, -60, -65, -65-1, -66, -67, 70 ................ Receptacle MS3470L14-5P -71, -73, -74, -76, -84 PN 4620-48, -50, -53, -85 ......................................................................... Cap Plug 1-480698-0
Leading Particulars Table 1
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
Pump Fluid Capacity (nominal): PN 4620-1, -2, -3, -3-13, -4, -6, -14, -17, -21, -27, -31, -32, -36, -37, -54, 12300 ....7.5 GPM PN 4620-8, -8-1, -9, -9-1, -10, -10-1, -16, -34, -39, -40, -43, -44, -48, -50, -51.........10 GPM -53, -55, -56, -57, -60, -65, -65-1, -66, -67, -68, -69, -70, -71, -73, -74, -76 -84, -85, -86, -87, -87-1, -90, -91, -92, -93, -94, -95, -96, -97, -98, -99, -100, -103, -104, -105, -106, -108, -108-1 Flushing Cycle (nominal)...................................................................................................8 seconds Tank Capacity (nominal): PN 4620-1, -67, -68, -69, -73, -84.................................................................................4.7 Gal PN 4620-2, -9, -9-1, -10, -10-1, -21, -32, -36 ...............................................................7.1 Gal PN 4620-3, -13, -31, -34, -43, -44, -57, -65, -65-1, -66, -70, -71, -105, 12300 ............8.7 Gal PN 4620-4, -14..............................................................................................................4.0 Gal PN 4620-6, -8, -8-1, -16, -27, -37, -54, -86, -87, -87-1, -100, -103, -108, -108-1 ........9.0 Gal PN 4620-17, -39, -56, -94, -106....................................................................................5.2 Gal PN 4620-40, -51, -92, -99, -104....................................................................................3.5 Gal PN 4620-48, -85..........................................................................................................14.0 Gal PN 4620-50 .................................................................................................................11.0 Gal PN 4620-53 .................................................................................................................15.5 Gal PN 4620-55, -60, -74, -76, -93, -95, -96, -97, -98.....................................................11.36 Gal
Leading Particulars Table 1 (cont)
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
INSTALLATION AND SERVICING 1.
General A.
2.
This section describes the procedures used for installation of the toilet assembly in the aircraft and servicing the toilet assembly. These procedures shall be performed at regular intervals or when deemed necessary.
Assembly Options A.
In order accommodate the variety of physical conditions and space considerations in all types of aircraft, these toilets have been designed to allow flexibility in assembly of the toilet bowl, the ground flush connection, the shroud and toilet seat, and the timer bracket. As shown in Figure 2, the toilet bowl and seat can be assembled to face either side of the tank. Shrouds are available in any size or dimension desired, to a maximum of 19 inches deep by 31 inches wide. Unless otherwise specified, toilet shrouds are supplied 18 by 21 inches which allows for a one inch trim on three sides to cover the toilet envelope without overhang. The toilet shroud is molded of Royalite plastic one-eighth inch thick and it can be cut or trimmed to suit the compartment design. The direction the bowl will face, however, determines the location of the flush button (if applicable) in the shroud
B.
The ground flush inlet fitting is also designed with a symmetrical mounting hole pattern which permits the inlet fitting to be mounted to face in any of four directions. For ease in making connection of electrical power from the aircraft to the toilet, the toilet timer bracket and the harness (if applicable) can be assembled on the tank top to face in any of four positions.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
LEGEND TO FIGURE The left hand part of the figure shows a typical aircraft installation in which the toilet is connected to a sewage drain line which terminates at a service panel on the exterior of the aircraft. In the upper right hand view, the toilet bowl is shown facing the slanted side of the tank and in the reverse position. Two of the four possible positions are shown for both the flush inlet fitting and the timer bracket. The stainless steel separator is interchangeable with the splash restrictor on some models.
Installation with Drain and Typical Options Figure 2
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
3.
Installation Dimensions The installation dimensions shown in Figure 3 illustrate the space requirements for the aircraft toilets covered by this publication. For specific dimensions of each toilet assy, utilize Figure 3 in conjunction with the appropriate dimension in Table 2 for the particular toilet model. In addition to the exact space required, a reasonable allowance must be made for unlatching and complete removal of the toilet from the aircraft where a sewer drain is not installed.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
A B C D E F G H
Floor to tank top Floor to toilet top Mounting frame side to side Mounting frame front to back Drain valve center Drain valve center Toilet left to right Toilet front to back
J K L M N P Q R S
Center of inlet fitting right to left Center of tank vent fitting right to left Drain valve center at top Drain valve center at top Drain opening (O.D.) Drain tube below floor Drain valve to toilet center Ground flush fitting tube size (O.D.) Drain valve cable thread connection
Installation Dimensions (Typical) Figure 3
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12300
Model
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2.80 8.52 19.00 16.00 12.00 2.00 3.25 8.97 3.75 N/A 3.16 0.62 *
E F G H J K L M N P Q R S
**
0.62
5.93
N/A
3.75
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.62
17.95
* - 10-32UNF-2A
11.79
D
4620-1
18.13
4620-2
C
**
0.62
5.93
N/A
3.75
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.68
18.11
16.03
**
0.62
5.93
4.20
4.00
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.68
18.11
16.03
** - 10-32UNF-3A
**
0.62
5.93
N/A
3.75
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.68
18.11
4620-3
14.23
4620-3-13
12.63
4620-4
16.17
15.75
20.56
12.00
23.50
2.87
4.34
8.68
*
0.62
8.75
5.50
4.17
3.75
6.00
*
0.62
8.75
5.50
4.17
3.75
6.00
21.87
20.56
12.00
23.50
2.87
4.34
8.68
21.75
15.75
*** - 10-32UNF-3B
***
0.62
6.22
N/A
3.75
13.90
3.32
N/A 21.87
2.00
13.31
17.31
N/A
N/A
N/A
N/A 21.75
12.30
4620-6
B
4620-8 11.18
*
0.62
8.75
5.50
4.17
3.75.
6.00
21.87
20.56
12.00
23.50
2.87
4.34
8.68
21.75
15.75
11.18
4620-8-1
11.18
*
0.62
5.93
1.83
4.48
3.38
3.38
5.88
15.38
16.00
19.00
2.82
2.82
11.62
17.95
14.23
9.72
4620-9
7.60
*
0.62
5.93
1.83
4.48
3.38
3.38
5.88
15.38
16.00
19.00
2.82
2.82
11.62
17.95
14.23
9.72
4620-9-1
11.52
*
0.62
5.93
1.83
4.48
3.38
3.38
5.88
15.38
16.00
19.00
2.82
2.82
11.62
17.95
14.23
9.72
4620-10
11.52
*
0.62
5.93
1.83
4.48
3.38
3.38
5.88
15.38
16.00
19.00
2.82
2.82
11.62
17.95
14.23
9.72
4620-10-1
9.72 15.75
11.18
**
0.75
5.80
0.38
4.17
13.57
3.38
2.09
2.09
13.50
17.50
N/A
N/A
N/A
*
1.00
8.75
0.50
4.60
3.75
6.00
8.25
20.56
12.00
23.50
2.87
4.34
8.68
N/A 21.75
12.10
7.59
4620-14
6.67
4620-16
11.50
**
0.62
8.20
0.43
4.17
20.50
6.80
N/A
2.10
13.50
20.50
N/A
N/A
N/A
N/A
12.30
7.60
4620-17
A
Monogram Systems
MAINTENANCE MANUAL PN 4620 and 12300 Series
Installation and Connection Dimensions Table 2 (Sheet 1)
Page 14 Dec 1/97
MM4620 **
0.62
5.93
N/A
3.75
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.68
18.11
* - 10-32UNF-2A
*
S
3.75
M
0.62
6.00
L
R
21.87
K
8.75
20.56
J
Q
12.00
H
N/A
23.50
G
P
2.87
F
4.17
4.34
E
N
8.68
Model D
4620-27 21.75
4620-31
C
4620-32 16.00
19.00
2.82
2.82
11.62
17.95
14.23
*
N/A
5.93
1.00
4.48
3.38
3.38
5.88
**
0.62
5.93
1.00
4.48
3.38
3.38
5.88
N/A 15.38
16.00
19.00
2.82
2.82
11.62
17.95
16.03
** - 10-32UNF-3A
N/A
0.62
5.93
0.50
4.64
3.38
3.38
5.88
15.38
16.00
18.94
2.82
2.82
11.62
17.95
14.23
4620-34
16.03
4620-36
15.75
4620-37
B
*
0.62
8.65
1.00
4.17
20.05
5.85
N/A
5.90
13.50
23.40
N/A
N/A
N/A
N/A
10.51
16.06
11.52
*
0.62
4.25
1.00
4.12
12.00
9.00
N/A
1.50
13.25
16.00
N/A
N/A
*
N/A
5.93
1.00
3.75
15.62
3.38
13.12
N/A
16.00
19.00
15.13
2.82
11.62
17.95
16.06
11.52
**
0.62
10.38
0.43
3.61
4.02
12.26
N/A
8.77
16.28
27.82
2.05
10.02
14.19
22.10
16.64
12.10
N/A
0.62
7.72
N/A
N/A
19.33
4.02
N/A
3.21
13.78
23.35
18.39
3.04
11.79
21.43
16.64
12.10
**** - 10-32UNF-THD
*
N/A
5.93
1.00
3.75
3.38
3.38
5.88
N/A
16.00
19.00
2.82
2.82
N/A 11.62
N/A 17.95
10.36
*** - 10-32UNF-3B
*
0.62
8.75
1.48
4.17
3.75
6.00
21.87
20.56
12.00
23.50
2.87
4.34
8.68
21.75
15.75
4620-39 5.75
4620-40
5.80
4620-43
11.18
4620-44
9.72
4620-48
11.52
4620-50
9.72 16.64
12.12
6.79
*
0.62
4.25
1.00
4.12
12.00
9.00
N/A
1.50
13.25
16.00
N/A
0.62
8.55
N/A
N/A
21.12
7.77
N/A
3.19
17.53
25.14
N/A 20.18
N/A
N/A 15.54
N/A 23.22
10.36
5.75
4620-51
11.52
4620-53
11.18
****
0.62
8.75
N/A
4.00
19.75
3.00
1.63
2.94
12.00
23.50
N/A
N/A
8.75
21.75
15.75
11.18
4620-54
A
Monogram Systems
MAINTENANCE MANUAL PN 4620 and 12300 Series
Installation and Connection Dimensions Table 2 (Sheet 2)
Page 15 Dec 1/97
MM4620
2.82
4.26
16.00
18.94
3.38
N/A
0.62
N/A
N/A
4.10
*
0.62
8.75
1.48
4.48
3.38
3.38
5.88
20.82
16.00
23.13
2.82
2.82
11.62
22.08
16.06
*
N/A
5.93
1.00
3.75
3.38
3.38
4.01
N/A
16.00
19.00
2.82
2.82
11.62
17.95
16.06
** - 10-32UNF-3A
*
0.62
5.93
1.48
4.48
N/A 15.56
N/A
N/A 13.06
5.90
13.50
23.40
N/A 15.13
N/A
N/A 11.62
N/A 17.95
* - 10-32UNF-2A
*
0.62
R
S
8.75
3.38
L
Q
17.25
K
1.48
2.31
J
P
16.00
H
4.48
23.13
G
N
19.20
F
19.75
2.82
E
M
11.62
Model
D
4620-55 22.08
4620-56
C
4620-57 16.06
4620-60
10.51
4620-65
16.06
4620-66
B
16.00
18.94
2.82
2.82
11.62
17.95
12.63
**
0.62
5.93
N/A
3.84
3.38
3.38
5.57
*
0.62
8.65
1.00
N/A
18.90
5.85
N/A
4.75
13.50
22.25
N/A
N/A
N/A
N/A
10.51
*** - 10-32UNF-3B
*
N/A
5.93
1.00
3.75
15.62
3.38
14.99
N/A 15.38
16.00
19.00
15.13
2.82
11.62
17.95
16.06
4620-67 5.80
4620-68
6.67 16.06
11.52
N/A
0.62
N/A
N/A
N/A
N/A
N/A
N/A
4.75
13.50
22.25
N/A
N/A
*
N/A
5.93
1.00
3.75
3.38
3.38
5.88
N/A
16.00
19.00
2.82
2.82
N/A 11.62
N/A 17.95
10.51
5.80
4620-69
11.52
4620-70
11.52
*
N/A
5.93
1.00
3.75
15.62
3.38
13.12
N/A
16.00
19.00
15.13
2.82
11.62
17.95
16.06
11.52
4620-71
11.52
*
0.62
5.93
N/A
3.75
15.56
12.62
2.25
3.31
16.00
18.94
14.92
8.80
11.62
17.95
11.18
6.67
4620-73
11.52
*
0.62
8.75
1.48
4.48
3.38
3.38
5.88
20.82
16.00
23.13
2.82
2.82
11.62
22.08
16.06
11.52
4620-74
5.80
*
0.62
8.75
1.23
3.68
3.38
3.38
5.88
20.82
16.00
23.13
2.82
2.82
11.62
22.08
16.06
11.52
4620-76
11.52
**
0.62
5.93
N/A
3.84
3.38
3.38
5.57
15.38
16.00
18.94
2.82
2.82
11.62
17.95
12.63
6.67
4620-84
A
Monogram Systems
MAINTENANCE MANUAL PN 4620 and 12300 Series
Installation and Connection Dimensions Table 2 (Sheet 3)
Page 16 Dec 1/97
4620-85
Model
MM4620 * - 10-32UNF-2A
N/A
S
4.02
M
0.62
12.26
L
R
N/A
K
10.38
8.77
J
Q
16.28
H
0.43
27.82
G
P
2.05
F
3.63
9.92
E
N
13.99
D
4620-86
22.00
*
*
*
0.62 0.62
8.75 8.75
1.48 1.48
4.48 4.48
3.75 3.75
6.00 6.00
20.56 20.56
7.25 7.25
12.00 12.00
23.50 23.50
2.90 2.90
4.34 4.34
8.68 8.68
21.74 21.74
15.75 15.75
** - 10-32UNF-3A
0.62
8.75
4.38
4.18
3.75
6.00
20.56
7.25
12.00
23.50
2.90
4.34
8.68
21.74
4620-87
C
4620-87-1
15.75
4620-90
17.62
*
0.62
5.93
1.48
4.48
3.38
3.38
N/A
15.63
16.00
18.62
2.82
2.82
11.62
17.95
N/A
*
N/A
4.25
1.00
4.12
4.00
4.25
N/A
16.50
13.25
16.00
N/A
N/A
N/A
N/A
10.36
*** - 10-32UNF-3B
*
N/A
5.93
1.48
4.48
3.38
3.38
N/A
15.38
N/A
18.62
2.82
2.82
11.62
17.95
N/A
4620-91
B
4620-92 *
N/A
8.75
1.48
N/A
3.38
3.38
5.88
N/A
16.00
23.13
N/A
N/A
N/A
N/A
16.06
11.52
4620-93
5.75
*
0.62
8.20
N/A
4.12
4.10
6.80
2.10
N/A
13.50
20.50
N/A
N/A
N/A
N/A
*
N/A
5.93
148
4.48
3.38
3.38
N/A
13.06
16.00
18.94
N/A
N/A
N/A
N/A
7.60 11.52 777.60 12.30 16.06
4620-94
6.67
4620-95/ -96
6.67
*
N/A
8.75
1.48
4.48
3.38
3.38
N/A
17.25
16.00
23.13
N/A
N/A
N/A
N/A
16.06
11.52
4620-97/ -98
11.18 11.18
*
N/A
4.25
1.00
4.12
4.00
4.25
N/A
N/A
13.25
16.00
N/A
N/A
N/A
N/A
10.36
5.75
4620-99
11.18
*
N/A
8.75
1.48
4.48
3.75
5.94
N/A
20.56
12.00
23.50
N/A
4.34
8.68
21.74
15.75
11.18
4620-100
12.10
*
N/A
8.75
1.48
4.48
3.75
6.00
7.25
20.56
12.00
23.50
N/A
N/A
N/A
N/A
15.75
11.18
4620-103
A
Monogram Systems
MAINTENANCE MANUAL PN 4620 and 12300 Series
Installation and Connection Dimensions Table 2 (Sheet 4)
Page 17 Jan 9/04
13.25
17.18
18.31
4.25
4.00
4.12
H
J
K
L
M
N
* - 10-32UNF-2A
*
16.00
G
S
N/A
F
N/A
N/A
E
R
N/A
D
4.25
N/A
C
4620-105
Q
10.36
Model
B
*
*
*
0.62 N/A
8.20 8.75
N/A 1.48
4.122 4.48
4.10 3.75
6.80 6.00
2.10 N/A
N/A 19.06
13.50 12.00
20.50 23.50
N/A N/A
N/A 4.34
N/A 8.68
N/A 21.74
12.30 15.75
11.18
** - 10-32UNF-3A
N/A
5.93
1.48
N/A
3.38
3.38
7.88
11.13
16.00
18.94
N/A
N/A
N/A
N/A
16.06
4620-106 7.60
4620-108
11.52
*
N/A
5.93
1.00
3.75
3.38
3.38
4.01
N/A
16.00
19.00
2.82
2.82
11.62
17.95
16.06
11.52
*** - 10-32UNF-3B
*
N/A
8.75
1.48
4.48
3.75
6.00
N/A
19.06
12.00
23.50
N/A
4.34
8.68
21.74
15.75
11.18
4620-1081
1.00
5.75
4620-65-1
P
4620-104
A
Monogram Systems
MAINTENANCE MANUAL PN 4620 and 12300 Series
Installation and Connection Dimensions Table 2 (Sheet 5)
MM4620
Page 17.1 Jan 9/04
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
PAGE INTENTIONALLY LEFT BLANK
MM4620
Page 17.2 Jan 9/04
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
4.
Installation Procedure A.
The following points should be considered when making the initial installation of the toilet within the aircraft: (1)
Measure toilet space requirements in accordance with the pattern shown in Figure 3 and refer to the appropriate dimension in Table 2 for the particular toilet model.
(2)
Make floor pattern layout in level area. The floor mounting frame (as applicable) can be drilled in any convenient pattern to suit the individual aircraft requirements. The frame to aircraft floor mounting should include a minimum of two bolts for each of the four rectangular sides of the frame.
(3)
Make certain that all of the hold down rods (as applicable) are correctly hooked into the mounting frame before the frame is bolted down. These rods cannot be attached to the frame, nor taken from it, when the frame is secured to the floor.
(4)
Toilet seat and shroud (as applicable) are not fastened to the toilet assembly. These items are designed to be readily lifted from the toilet for ease of cleaning and servicing or if maintenance is needed. Provision for suitable fastening of toilet seat and shroud must not be overlooked when making initial installation. Toilet compartment trim in the form of detachable strips can be used if desired. Suitable allowance should be made for raising the shroud to provide access to the tank holddown rods and the handles for lifting the toilet assembly out of its mounting.
(5)
If toilet is being installed over a sewage drain in the aircraft, provision should be made for making a cable connection to the toilet drain valve cable which can be routed as necessary to terminate at the aircraft service panel.
MM4620
Page 18 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
TESTING AND FAULT ISOLATION 1.
2.
General A.
This section describes the equipment and procedures used for testing and fault isolation of the toilet assembly or a detail component assembly. These procedures shall be performed when a problem is suspected.
B.
Testing and fault isolation shall be carried out at ambient room conditions: (1)
Temperature
+68 ? 27? F (+20 ? 15? C)
(2)
Relative Humidity
50 ? 40 %
(3)
Atmospheric Pressure
28.4 ? 2.2 in. Hg (960 ? 75 hPa)
Equipment and Materials A.
Refer to Table 3 for the required test equipment. NOTE:
Equivalent substitutes may be used for listed items.
ITEM
IDENTIFICATION
SOURCE
DC Power Supply 0 - 30 VDC
---
Commercially Available
Water Regulator 0 - 50 psig (0 - 34,5 bars)
---
Commercially Available
Pressure Gage 0 - 50 psig (0 - 34,5 bars)
---
Commercially Available
DC Ammeter 4 Amps minimum
---
Commercially Available
Flowmeter 0 - 15 gpm ( 0 - 56,8 lpm)
---
Commercially Available
Test Equipment Table 3
MM4620
Page 19 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
3.
Testing Procedures A.
Toilet Assembly Functional Test (1)
Set up toilet assembly to be tested as shown in Figure 4.
(2)
Open the water supply valve (6) and fill approximately 2 to 5 gallons of water into the tank. For motor pump filter assemblies with a fixed filter basket, hold bowl separator flapper (11) in open position and visually determine that tank is being sprayed by the spray nozzle of the motor pump filter assembly as the tank fills.
(3)
Inspect the drain valve outlet for leaks; no leaks are permitted.
(4)
Turn on the electrical power supply (8).
(5)
Depress toilet flush pushbutton; the motor pump filter assembly should operate and all interior surfaces of the toilet bowl should be vigorously washed by the flushing fluid. Flushing action continues for approximately 9 seconds.
(6)
Cap the vent fitting on the toilet assembly.
(7)
Open the water supply valve (6) and fill the toilet assembly unit the water level is approximately 1.0 in. (25.4 mm) below the top of the bowl. Remove any air trapped within the tank.
(8)
Allow the toilet to remain in this condition for one hour after which there shall be no evidence of leakage from any of the toilet components including the toilet tank, tank top, gaskets and fittings.
(9)
Open tank drain valve assembly (14) and drain approximately 1 gallon (3,78 liters) of water from the toilet tank; close the tank drain valve.
(10) Inspect the drain valve outlet for leaks; no leaks are permitted. (11) Repeat Steps (9) and (10) several times or until the toilet tank is empty. (12) Disconnect and remove toilet assembly from the test setup. Use dry compressed air to completely dry the toilet assembly inside and outside.
MM4620
Page 20 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11 12. 13. 14.
Unit Under Test Suitable Support Fixture Water Drain Hose Water Regulator, set between 24 and 26 PSI (16,56 - 17,94 Bars) Pressure Gage, 0 to 50 PSI (0 - 34,5 Bars) Water Supply Valve Check Valve DC Electrical Power Supply with Ammeter, 28 VDC, 4 Amps minimum or 115/200 VAC 3-Phase, 400 Hz Timer Assembly with Flush Pushbutton Bowl Assembly Separator Assembly Grounding Cable Motor Pump Filter Assembly Drain Valve Assembly
Toilet Assembly Test Setup (Typical) Figure 4
MM4620
Page 21 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
B.
Cartridge or Motor Pump Filter Assembly Test (1)
Set up cartridge or motor pump filter assembly to be tested as shown in Table 4.
(2)
Open water supply valve (9) and fill water container to a height of 2 in. (51 mm) below the bottom of the unit mounting flange.
(3)
Turn on electrical power supply (6).
(4)
Observe and record flowmeter (5), and ammeter (6); reading shall be as follows:
CARTRIDGE OR MOTOR PUMP FILTER ASSEMBLY PN
FLOWRATE Gpm
VOLTAGE
CURRENT DRAIN (nominal)
3500-4, -5, -6, -8
6.5 ? 1
28 VDC
5.0 A
3500-7, -9, -10, -11, -12, -13,
7.5 ? 1
28 VDC
4.5 A
8.5 ? 1.5 10 ? 1
28 VDC 28 VDC
4.0 A 4.0 A
3519-004
12 ? 1
28 VDC
4.0 A
4910-101-11, -15
6.5 ? 1
28 VDC
7.0 A
4910-101-13, -14
10 ? 1
115/200 VAC 3-phase 400 Hz
0.8 A per phase (operating) 1.2 A per phase (stall)
3500-14, -15 3511-001, -003, -004, -007, -010, 3512-004
Pump Output Table 4 (5)
Repeat Step (4); observe that the flow and pressure is within 1 GPM (3,78 LPM) of those recorded in Step (4).
(6)
Disconnect and remove motor pump filter assembly from test setup. Use dry, compressed air to completely dry the motor pump filter assembly inside and outside.
MM4620
Page 22 Jan 9/04
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
1. 2. 3. 4. 5. 6. 7. 8. 9.
Unit Under Test Suitable Support Fixture Water Container Manometer (optional), 0 to 1.0 PSIG (0 to 0,69 Bars) Flowmeter, 10 to 20 GPM at 0.5 to 10 PSIG (37, 85 to 75,7 LPM at 0,345 to 6,9 Bars) Electrical Power Supply with Ammeter, 28 VDC, 4 Amps Minimum or 115/200 VAC 3-Phase, 400 Hz Grounding Cable Toilet Flush Control Assembly Water Supply Valve
Cartridge or Motor Pump Filter Assembly Test Setup (Typical) Figure 5
MM4620
Page 23 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
C.
Drain Valve Assembly Test The test procedures described apply to a completely assembled valve assembly. The test facility requirements consist of a mounting frame to support the valve assembly with the mounting plate secured in the horizontal position and a Hunter force gauge (or spring scale) to measure pull force of 0 to 50 lb. (0 to 22,68 Kg). (1)
Secure the drain valve assembly in the test mounting frame.
(2)
Attach a suitable hook or quick-disconnect to the drain valve cable assembly.
(3)
Measure the distance between the lower surface of the housing mounting plate to the bottom of the threaded sleeve of the valve stem assembly. Record this measurement.
(4)
Connect the force gauge on the spring scale to the cable; apply a steady pull on the cable assembly until the valve stem has reached the fully compressed position. NOTE:
The cable force must be applied parallel to the mounting plate surface and in line with the pulley.
(5)
Note and record the pull force required to retract the valve stem assembly.
(6)
The pull force recorded should be as follows: NOTE:
In the event that the unit fails to meet the test requirements, refer to Troubleshooting.
DRAIN VALVE ASSEMBLY PN 4631-16, -26, -36, -36-10, -49, -65, 4650-1, -4, -8, -9, -12, -13, -14, -15, -16, -19, 12230-1, 12300-11 4631-56
Minimum Pull Force (lbs)
Maximum Pull Force (lbs)
30
35
15
20
Cable Pull Force Table 5
MM4620
Page 24 Dec 1/97
Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
D.
Toilet Timer Assembly Test The test checks the timer for a “flushing” cycle of 9 ? 1 seconds after the pushbutton switch is operated. (1)
Referring to Figure 6, connect a 28 VDC motor pump filter assembly and a flush pushbutton switch to the timer assembly.
(2)
Submerge the pump portion of the motor pump filter assembly into a container of water.
(3)
Connect a 28 VDC power source to the timer assembly.
(4)
Turn on power source
(5)
Obtain a precision timing instrument and reset it to zero. Hold timing instrument in one hand and flush pushbutton in the other hand, press the pushbutton and start the timing instrument at the same time. The motor pump filter assembly shall operate for 9 ? 1 seconds.
(6)
Disconnect power and remove timer assembly from test setup. NOTE:
If the timer assembly fails the test, refer to Fault Isolation.
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Toilet Timer Assembly Test Setup (Typical) Figure 6
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E.
Liquid Level Transmitter Test The test checks the signal from the liquid level transmitter when a low or PRECHARGE condition exists and when a FULL condition exists. (1)
Install the toilet assembly normally in the aircraft or on a test stand.
(2)
Connect the appropriate harness to the level sensor. A test harness is shown is Figure 7.
(3)
Fill the toilet assembly with a minimum of 2 gal (8 l) of water.
(4)
Verify that the PRECHARGE indicator light is on.
(5)
Continue to fill the toilet with water until the water level is approximately underneath the water separator.
(6)
Verify that the FULL indicator light is on.
(7)
Drain all the water in the toilet assembly.
(8)
Verify that the PRECHARGE and FULL indicator lights are off.
(9)
If the LLT is not working properly replace the LLT and repeat the test.
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LLT Test Harness Setup Figure 7
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4.
Fault Isolation A.
Toilet Assembly (refer to Table 6) Problem
Toilet will not cycle.
Possible Cause
Corrective Action
Aircraft power not on.
Check aircraft power, fuses, circuit breakers.
Defective wiring
Check all wiring for continuity.
Defective timer (if applicable) Replace timer. Defective motor Toilet cycles but flush liquid not pumped into bowl.
Replace motor.
Inadequate flush liquid charge Charge the toilet. Refer to in tank. Filter not completely Servicing instructions. submerged. Filter clogged.
Clean filter. Refer to Cleaning.
Defective motor.
Replace motor.
Filter clogged causing excessive motor load.
Clean filter. Refer to Cleaning.
Check valve assembly stays open.
Mushroom valve defective.
Replace mushroom valve.
Leakage from top of drain valve assembly.
Damaged bellows boot on drain valve.
Replace drain valve boot.
Toilet has excessive odor
Excess usage.
Service toilet. Refer to Cleaning.
Improper deodorant used.
Use recommended chemical.
Excessive noise during cycling.
Fault Isolation Table 6
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B.
Cartridge or Motor Pump Filter Assembly (refer to Table 7) Problem
Possible Cause
Corrective Action
Motor does not run.
Open circuit to the motor.
Repair wiring.
Pump delivers low fluid flow.
Clogged filter basket.
Clean filter basket.
Toilet will not flush (motor pump filter running).
Foreign object obstructing flushing fluid passages.
Remove motor pump filter unit, toilet bowl and separator. Inspect for obstruction in flushing fluid passages.
Low volume flushing.
Drain valve not seated properly.
Inspect drain outlet valve seat area of the tank for cracks, chips and deep scratches. Check drain valve compression.
Impeller damaged.
Replace impeller.
Motor not making full contact with drive shaft.
Remove, inspect and reinstall motor.
Pump inoperative.
Sheared drive shaft.
Replace drive shaft.
Spray nozzle assembly will not rotate, motor pump inoperative.
Spray nozzle not installed properly.
Remove and reinstall spray nozzle.
Spray nozzle assembly does not spray adequately.
Spray nozzle assembly clogged.
Clean spray nozzle.
Motor runs continuous or excessively long.
Malfunction in timer assembly.
Replace timer.
Motor running hot.
Bearing(s) worn.
Replace motor.
Noisy rotor shaft assembly
Worn bearings
Replace motor.
Fault Isolation Table 7
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C.
Drain Valve Assembly (refer to Table 8) Problem
Valve full retracts at less than 30 lb. (13,6 kg)
Valve requires over 35 lb. (15,9 kg) force to retract.
Possible Cause
Corrective Action
One spring not installed.
Install correct number of springs.
Weak or wrong spring(s).
Install new correct spring(s).
Cable is binding.
Replace cable assembly.
Valve stem assembly or spring binding in housing assembly.
Disassemble valve stem assembly inspect the inside and outside surfaces of the valve stem assembly tube and springs for evidence of scraping and scouring. Replace parts as necessary.
Fault Isolation Table 8
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D.
Timer Assembly (refer to Table 9) Problem
Possible Cause
Corrective Action
Flush cycle is not 9 ? 1 seconds.
Defective printed circuit board.
Replace printed circuit board.
Pump motor does not run at full speed or does not run.
Defective printed circuit board or pushbutton switch.
Replace printed circuit board.
Defective pushbutton switch.
Replace pushbutton switch.
Fault Isolation Table 9
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E.
Liquid Level Transmitter Assembly Refer to Testing to determine probable faults and corrective action.
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CLEANING 1.
General WARNING:
2.
CLEAN PARTS IN A WELL LIT AREA WITH GOOD AIR CIRCULATION. ENSURE SAFETY AND FIRE EQUIPMENT ARE AVAILABLE AT ALL TIMES.
A.
Clean all metal parts to remove oil, grease, rust, and dirt. Clean the flange areas and sealing surfaces to remove old sealing compounds.
B.
Use a bristle brush to remove loose scale and light surface corrosion.
Equipment and Materials Standard shop equipment such as soft bristle brushes may be used to clean the parts. Refer to Table 10 for materials. NOTE:
Equivalent substitutes may be used for listed items. ITEM
DESCRIPTION
SOURCE
Disinfectant
Lysol
Commercially available
Soap
Antimicrobial
Commercially available
Isopropyl Alcohol
---
Commercially available
Cloth, Lint-free
---
Commercially available
Cleaning Materials Table 10
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3.
Cleaning Procedures WARNING:
A FACE GUARD AND GLOVES (ELBOW LENGTH) SHOULD BE WORN WHILE STEAM CLEANING FOR PROTECTION FROM BACK SPLASH.
The following methods and materials should be used for cleaning the toilet before disassembly and also for cleaning the disassembled components. Cleaning agents are specified in Table 10. A.
Cleaning Procedure (1)
Steam clean the toilet assembly with appropriate care to avoid excessive heat and steam on rubber and electrical items. The toilet may be cleaned by hand using bristle brushes and a strong solution of hot soapy water and disinfectant. Rinse thoroughly with clean water and dry completely with a cloth or warm dry air.
(2)
Wash all mechanical parts in a strong solution of hot soapy water and disinfectant. A mild vinegar solution may also be used to remove hard water deposits.
(3)
Clean wired and electrical parts by hand, using a cloth and brush moistened sparingly with isopropyl alcohol.
(4)
Clean the drain valve by hand, using bristle brushes and a strong solution of soap and water. Dry thoroughly.
(5)
Clean the filter section of the cartridge, using a strong solution of soap and water, rinse thoroughly with clean water and dry completely.
(6)
Wipe the timer (if applicable) with a soft lint free cloth moistened sparingly with isopropyl alcohol.
(7)
Clean the tank by hand, using a strong solution of disinfectant, hot soapy water and bristle brush. Rinse thoroughly with clean hot water and dry completely.
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INSPECTION 1.
General A.
The complete assembly and component subassemblies shall be visually inspected using a strong light and preferably some means of magnification. When inspecting for damage to interior details of an assembly, an inspection mirror shall be used so that all surfaces are made visible.
B.
All parts shall be visually examined for nicks, cracks, cuts, fraying, dents, distortion, chafing, scoring, excessive wear, loose or missing mounting rings and screws, stripped or crossed threads and other defects that could impair function of the toilet. Parts made of rubber or neoprene shall be replaced at each overhaul; therefore, inspection of rubber packings, seals, mushroom valve and gaskets is unnecessary.
C.
To conduct an electrical check of Liquid Level Transmitter Assembly refer to schematic diagram in Figure 9.
D.
Refer to wiring diagram, Figure 8 to check continuity of electrical wiring on Timer Assembly.
E.
Conduct a detailed inspection of parts and assemblies in accordance with the requirements of Inspection and Check, Table 11.
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2.
Check Procedures A.
To conduct an electrical check of toilet assembly, refer to electrical schematic, Figure 8.
B.
Conduct a detailed inspection of the toilet assembly as shown in Table 11. PART
INSPECT FOR
Top and Tank Assembly
Deformation, delamination, cracks, nicks, scratches, loose mounting plates, broken, stripped, or otherwise damaged threads, cracked, nicked, scratched or deformed drain outlet seat.
Stator and rotor windings and electrical cable
Damaged or deteriorated insulation, broken wires, chafing and scoring broken electrical leads.
Spray nozzle, impeller housing cover plates and mushroom valve
Cracks, nicks, cuts, distortion, chafing, scoring, and excessive wear.
Pump drive shaft and coupling
Chipped, cracked or broken coupling and bent shafts.
Impeller
Cracks, nicks, distortion, erosion.
Pulley
Bearing freedom and smoothness, nicks and chips.
Cable Assembly
Fraying, kinks, broken strands and ball swagging.
Cover Assembly
Bending, deformation and broken spot welds.
Housing Assembly
Bending, deformation, dents and stripped threads.
Valve Stem Assembly
Bending, deformation, dents, nicks, scratches, chafing, scoring and stripped threads.
Springs
Distortion, cracks and dimensions
Electrical Connectors
Evidence of arcing or burning, broken or bent pins, foreign material in connector.
Inspection and Check Table 11
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C.
Inspection and Cleaning of Filter (P/N 3500-4 thru -14, 4910-101-11, -13, -14, -15) If toilet flushing action is not satisfactory, check condition of filter basket in toilet tank through the bottom of toilet bowl with gloved hand. If the filter seems to be clogged with paper pulp or foreign material, perform the following steps: (1)
Inspect filter condition closely by use of a mirror and light, working through the bottom of the bowl.
(2)
Clean material from slots in filter basket with a brush.
(3)
Open drain valve and rinse toilet thoroughly as described in the preceding steps for servicing.
(4)
Close drain valve and fill tank with approximately two gallons of clear water.
(5)
Operate toilet for at least three complete flush cycles.
(6)
Re-inspect filter basket and re-clean if necessary. NOTE:
The type of materials most likely to cause clogging of the filter are: sanitary napkins, fabrics, flexible plastic bags, stranded or stringy items such as ribbons, cords and hair.
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Toilet Wiring Diagrams Figure 8 (Sheet 1)
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MODELS 4620-86, 4620-87, -87-1
MODELS 4620-43, 4620-44, 4620-65, -65-1, 4620-66, 4620-67, 4620-76, 4620-84
Toilet Wiring Diagrams Figure 8 (Sheet 2)
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TERMINAL BOARD
MS3470L14-5P
MS3470L14-5P CONNECTOR THERMAL PROTECTOR
THERMAL PROTECTOR
Toilet Wiring Diagrams Figure 8 (Sheet 3)
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Transmitter Schematic Diagram Figure 9
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DISASSEMBLY 1.
General NOTE:
2.
See TESTING AND FAULT ISOLATION to establish the condition of a component or most probable cause of its malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the component.
A.
Since this manual is used with all 4620 and 12300 series toilet assemblies, the disassembly instructions that follow provides only general instructions and special procedures. In most cases the disassembly is not complicated.
B.
Prior to initiating disassembly operations, personnel shall carefully read all instructions and study illustrations applicable to the toilet assembly or component. The applicable IPL4620 Series manual must be available. The toilet assembly or component shall be in a clean condition, free of contamination and residue, before disassembly is begun. Refer to CLEANING if additional cleaning is required.
Equipment and Materials A.
Standard shop equipment and materials can be used to disassemble the unit.
B.
At each overhaul O-rings, gaskets, and attaching hardware shall be replaced, unless otherwise specified.
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3.
Disassembly Procedures A.
Disassembly of a toilet assembly: Only a badly worn or damaged component should be removed from the toilet assembly. Unnecessary disassembly is not recommended. The following instructions are general guidelines for disassembling a toilet assembly. Refer to the applicable IPL4620 manual for the illustrated parts list of the toilet assembly. NOTE:
Item numbers appearing on the illustrated parts list are grouped in a manner to remove a component or assembly. Check for hardware and gaskets or seals which must be in place when the toilet assembly is re-assembled. Refer to INTRODUCTION, Table I for the cross-reference of a 4620 series or 12300 series toilet assembly to its applicable IPL4620 series manual.
NOTE:
Replace any item found to be damaged or worn. Replace all removed parts such as gaskets, seals, O-rings and rubber or neoprene parts.
NOTE:
The procedures described are typical. In some instances another component(s) may need to be removed first before gaining access to the desired component.
(1)
Removal of the toilet bowl. (a)
Disconnect flush hose to bowl.
(b)
Note or mark direction bowl is pointing in reference to tank top.
(c)
Remove nuts and washers from base of bowl.
(d)
Remove bowl and gasket. Splash restrictor or separator assembly may also be removed if stuck to the bottom of the bowl. NOTE:
On toilets equipped with a separator assembly, note the direction of the drainage caused by the separator assembly in reference to the top of toilet (typically, waste falls into the tank away from the cartridge). If the separator assembly is installed wrong, the result may impede performance of the toilet.
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(2)
(3)
(4)
Removal of the cartridge or motor pump filter assembly. (a)
Disconnect electrical wiring to cartridge or motor pump filter assembly.
(b)
Disconnect flush hose(s) to cartridge or motor pump filter assembly.
(c)
Note or mark direction cartridge or motor pump filter assembly is pointing in reference to tank top.
(d)
Remove nuts and washers securing cartridge or motor pump filter assembly.
(e)
Remove cartridge or motor pump filter assembly and gasket.
Removal of the drain valve assembly. (a)
Where applicable, remove drain valve cable from toilet tank top pulley(s) and bracket(s).
(b)
Note or mark direction drain valve assembly is pointing in reference to tank top.
(c)
Remove nuts and washers securing drain valve assembly.
(d)
Remove drain valve assembly and gasket.
Removal of the timer assembly. (a)
Tag and disconnect connectors from timer as applicable.
(b)
Remove attaching screws from timer as applicable.
(c)
Remove timer.
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(5)
(6)
Removal of the check valve assembly. (a)
Disconnect hose(s) to check valve assembly.
(b)
Note or mark direction check valve assembly is pointing in reference to tank top.
(c)
Remove nuts and washers securing check valve assembly.
(d)
Remove check valve and gasket. Some applications have a check valve adapter and O-rings.
Removal of the liquid level transmitter. (a)
Disconnect connector to liquid level transmitter.
(b)
Note or mark direction liquid level transmitter is pointing in reference to tank top.
(c)
Remove four screws and washers securing the liquid level transmitter.
(d)
Remove liquid level transmitter and O-ring.
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B.
Disassembly of a component assembly. The following instructions are general guidelines for disassembling a component assembly. Refer to the applicable IPL4620 manual for the illustrated parts list of the component assembly. NOTE:
(1)
Refer to INTRODUCTION, Table I for the cross-reference of a 4620 series or 12300 series toilet assembly to its applicable IPL4620 series manual.
Disassembly of a cartridge or motor pump filter assembly. There is no particular sequence that must be followed to disassemble a cartridge or motor pump filter assembly. The breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. Deviations are permitted to allow removal of a desired part.
(2)
Disassembly of a drain valve assembly. There is no particular sequence that must be followed to disassemble a drain valve assembly. The breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. Deviations are permitted to allow removal of a desired part. The following are general instructions to disassemble a drain valve assembly. NOTE:
Before disassembling the drain valve assembly, note the direction of the cover assembly with respect to the housing assembly. Its orientation is important to provide the proper direction of the cable assembly. On some drain valve assemblies the cover can be mounted in any direction with no adverse affect and does not have to be noted.
(a)
Remove cotter pins, washers, clevis pins, and pulleys from top of drain valve cover.
(b)
Where applicable, remove hardware from bottom of drain valve securing drain valve cable.
(c)
Remove cable assembly by pulling it out from the bottom of the valve.
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(d)
Remove cover assembly from housing by removing nuts and washers. WARNING:
(3)
Cover assembly is spring loaded in the installed condition. Exercise care while removing to avoid possible injury.
(e)
Remove springs and washers from inside of drain valve.
(f)
Where applicable, loosen clamp or remove spirolox on top of boot to permit boot to slide on housing.
(g)
Push stem assembly into housing and remove exposed spirolox as it protrudes out of the top of housing.
(h)
Remove housing from stem assembly.
(i)
Remove loosened clamp or spriolox from Step (f).
(j)
Remove nut and holding plate from bottom of drain valve stem.
(k)
Remove seal plug, support plate and boot.
Disassembly of a timer assembly. There is no particular sequence that must be followed to disassemble a timer assembly. The breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. Deviations are permitted to allow removal of a desired part. (a)
Removal and replacement of a printed circuit board is permitted, but replacement of parts on the circuit board is not recommended.
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(4)
Disassembly of a check valve assembly. There is no particular sequence that must be followed to disassemble a check valve assembly. The breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. Deviations are permitted to allow removal of a desired part. (a)
(5)
Some check valve assemblies have a cap that can be mounted at different directions is relation to the body. Note or mark direction of the cap with respect to the body
Disassembly of a liquid level transmitter. There is no particular sequence that must be followed to disassemble a liquid level transmitter assembly. The breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. Deviations are permitted to allow removal of a desired part. (a)
Removal and replacement of a printed circuit board is permitted, but replacement of parts on the circuit board is not recommended.
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REPAIR 1.
General Except for permissible repairs outlined in this section, repair of the top and tank assembly, detail parts and subassemblies is not considered practicable; parts which do not meet inspection requirements shall be replaced. In addition to permissible repairs and replacements of defective parts, certain parts replacement shall be routine at each overhaul regardless of apparent condition of the part. All nuts, washers, gaskets and O-rings removed during disassembly procedure shall be replaced regardless of apparent condition.
2.
Equipment and Materials NOTE:
Equivalent substitutes may be used for listed items.
ITEM
DESCRIPTION
SOURCE
Aluminum Oxide Abrasive Cloth
Federal Specification P-C-451; Grade 600
Commercially Available
Primer
MIL-P-23377, Class 1
Commercially Available
Epoxy, Enamel
MIL-C-22750, Color No. 16307 per Fed. Std 595
Commercially Available
Paint
Gull Gray Gloss Lacquer Color Number 32251 Specification MIL-L-7178
Any Government Approved Source
Repair Materials Table 12
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3.
Repair Procedures A.
Top and Tank Assembly Due to structural considerations, cracks, fractures, delamination and ruptures of the top and tank assembly necessitates replacement or factory repair.
B.
Motor-Pump-Filter Assembly (1)
Motor Assembly Brush holder cap and Brush assembly are the only replaceable parts within the motor assembly.
(2)
Refinish Refinish exterior painted surfaces of the motor assembly as follows:
(3) C.
(a)
Sand all chipped, loose paint and corroded areas of the motor assembly.
(b)
Paint all exposed areas of motor assembly with one coat of epoxy primer and a coat of epoxy enamel.
Replace all damaged or otherwise illegible nameplate identification or decals.
Drain Valve Assembly (1)
Deburring and chasing of stud threads and threaded fittings is acceptable as long as no more than two consecutive threads are damaged.
(2)
Dimpled mounting plate holes may be flattened as long as hole diameter deformation does not occur.
(3)
Part number identification removed or otherwise destroyed shall be re-applied.
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D.
Timer Assembly (1)
Except for permissible repairs described in this section, repair of the timer assembly is not considered practicable. Replace all parts that do not meet INSEPECTION requirements.
(2)
Repair damage to painted surfaces of case and mounting plate as follows (refer to Table 12 for repair materials). (a)
Lightly sand the damaged area with aluminum oxide abrasive cloth, Federal Specification P-C-451, Grade 600, or finer, making certain to feather edge of sanded area into surrounding painted area.
(b)
Apply a primer coat, Specification MIL-P-23377 to exposed metal surfaces.
(c)
When dry, lightly sand primer as in step (a).
(d)
Apply a finish coat of Gull Gray Gloss Lacquer, Color No. 32251, Specification MIL-L-7178.
(e)
Repair electrical wiring in accordance with standard shop practices.
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ASSEMBLY 1.
2.
General A.
Assembly instructions given herein presume the toilet assembly or component has been disassembled to the extent covered in DISASSEMBLY. All part number identification removed during cleaning or otherwise illegible, has been replaced during repair. All new parts are identical in fit and function to the parts they replace.
B.
Refer to Table 13 for assembly materials. Hardware items like bolts, washers, nuts and parts made of rubber, removed during disassembly, should be replaced with new parts.
C.
Each of the following paragraphs describes assembly of a toilet assembly or a component assembly.
Equipment and Materials Standard shop equipment and tools can be used to assemble the unit. Refer to Table 13 for assembly materials. NOTE:
Equivalent substitutes may be used for listed items.
ITEM
DESCRIPTION
SOURCE
Lockwire Threadlock
MS20995C32 8421 Grade C
Commercially available. Loctite Corp. 1001 Trout Brook Crossing Rocky Hill, CT 06067-3910
Lubricant
Lubriplate No. 105
Fiske Bros. Refining Co. Newark, NJ 73219
Shrink Tubing
RNF-100 X 1/4 ID RNF-100 X 3/8 ID
Raychem Corp. 300 Constitution Dr. Menlo Park, CA 94025
Assembly Materials Table 13
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ITEM
DESCRIPTION
SOURCE
Sealant
P/S 890 Class A
PRC-De Soto 5454 San Fernando Glendale, CA 91209
Lubricant
Dow Corning 111
Dow Corning Corp. Midland, MI 48640
Assembly Materials Table 13 (cont)
3.
Assembly Procedures A.
Assembly of a toilet assembly: NOTE:
Item numbers appearing on the illustrated parts list are grouped in a manner to remove a component or assembly. Check for hardware and gaskets or seals which must be in place when the toilet assembly is re-assembled. Refer to INTRODUCTION, Table I for the cross-reference of a 4620 series or 12300 series toilet assembly to its applicable IPL4620 series manual.
NOTE:
Replace any item found to be damaged or worn. Replace all removed parts such as gaskets, seals, O-rings and rubber or neoprene parts.
NOTE:
The procedures described are typical. In some instances another component(s) may need to be removed first before gaining access to the desired component.
(1)
Installation of the toilet bowl. (a)
If removed, install splash restrictor or separator assembly with a new gasket. NOTE:
(b)
On toilets equipped with a separator assembly, install the separator assembly at the correct angle in reference to the tank top (typically the waste should fall into the tank away from the cartridge). If the separator assembly is installed wrong, the result may impede performance of the toilet.
Install bowl at the correct angle with a new gasket.
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(2)
(3)
(4)
(c)
Install nuts and washers on base of bowl.
(d)
Connect flush hose to bowl.
Installation of the cartridge or motor pump filter assembly. (a)
Install cartridge or motor pump filter assembly at the correct angle in reference to the tank top with a new gasket.
(b)
Install nuts and washers securing cartridge or motor pump filter assembly.
(c)
Connect flush hose(s) to cartridge or motor pump filter assembly.
(d)
Connect electrical wiring to cartridge or motor pump filter assembly.
Installation of the drain valve assembly. (a)
Install drain valve assembly at the correct angle in reference to the tank top with a new gasket.
(b)
Install nuts and washers securing drain valve assembly.
(c)
Where applicable, install drain valve cable to toilet tank top pulley(s) and bracket(s).
Installation of the timer assembly. (a)
Install timer assembly.
(b)
Install attaching screws on timer as applicable.
(c)
Connect connectors to timer as applicable.
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(5)
(6)
Installation of the check valve assembly. (a)
Install check valve at the correct angle in reference to the tank top with a new gasket. Some applications have a check valve adapter and O-rings. Use new O-rings. Apply lubricant (Dow Corning 111) to O-rings before installation.
(b)
Install nuts and washers securing check valve assembly.
(c)
Connect hose(s) to check valve assembly.
Installation of the liquid level transmitter. (a)
Install liquid level transmitter at the correct angle in reference to the tank top with a new O-ring. Apply lubricant (Dow Corning 111) to O-ring before installation.
(b)
Install four screws and washers securing the liquid level transmitter.
(c)
Connect connector to liquid level transmitter.
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B.
Assembly of a component assembly. The following instructions are general guidelines for assembling a component assembly. Refer to the applicable IPL4620 manual for the illustrated parts list of the component assembly. NOTE:
(1)
There are two basic types of cartridges or motor pump filter assemblies. Early models have a rotating filter basket, where the basket rotates to clean itself of debris. Later models have a fixed filter basket, where the basket does not move and a spray nozzle inside the basket cleans the basket of debris.
Assembly of a cartridge or motor pump filter assembly (with rotating filter basket). There is no particular sequence that must be followed to assemble a cartridge or motor pump filter assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general assembly sequence. The following special procedures, where applicable, should be followed during assembly. (a)
For applications with a closed gear box (i.e. grease retainer PN 3315 and gear housing PN 3304), pack cavity with grease to reduce noise level and minimize migration. See Figure 10.
Gear Box Grease Application Figure 10
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
(b)
(2)
For applications with clutch mechanisms (i.e. clutch spring PN 4910-29-2 and pressure plate PN 4910-29-9), tighten nut, PN HO1-3, until the slip torque of clutch mechanism is 5.0 ? 0.5 in.-lbs when shaft PN 4911-1, 2 or -3 is rotated in the unit in either direction. See Figure 11.
Assembly of a motor pump filter assembly (with fixed filter basket). There is no particular sequence that must be followed to assemble a motor pump filter assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general assembly sequence. The following special procedures, where applicable, should be followed during assembly. (a)
When install mounting plate (PN 3516-001) on frame (PN 3514-001, -003 or -005) apply a uniform film of sealant (P/S 890, Class A) to bond the two together. Install mounting plate on frame using screws, washers and nuts. Apply sealant to periphery and screw heads after installation to ensure a water tight seal.
(b)
Install flapper, PN 16202-020, by pulling installation tail through hole in antisiphon housing. Trim tail 0.010 - 0.030 in. (0,25 - 0,76 mm) from bulb if new flapper is being used.
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(c)
When installing the drive shaft and impeller, add thrust washer(s) on top to provide full engagement of drive shaft to motor. Impeller must have a minimum clearance of 0.005 in. between impeller and housing. Add thrust washer(s) in middle to obtain this clearance. Thrust washer(s) on bottom are added last to take up excessive slack. See Figure 12.
Seal Lubrication Figure 11
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
(e)
When installing adapter plate on motor, apply threadlock (Loctite 8421) to threads of screws before installation.
(f)
When installing the motor, insert motor shaft into drive shaft coupling as shown in Figure 14. Ensure motor shaft is fully engaged with drive shaft coupling. Torque bolts 20 to 25 in.-lb and install safety wire (MS20995C32) in accordance with MS33540, double twist method.
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(3)
Assembly of a drain valve assembly. There is no particular sequence that must be followed to assemble a drain valve assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general disassembly sequence. The following are general instructions to assemble a typical drain valve assembly. (a)
Insert valve stem, support plate, and seal plug through the base of the boot. NOTE:
(b)
Support plate flange must be installed facing down.
Install the holding plate on drain valve stem so that the lip of the boot is sandwiched between the plate and support plate as shown in Figure 15.
Boot Installation Figure 12
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(c)
Secure parts in place with nut.
(d)
Slide clamp or spirolox(es) over boot. Do not tighten at this step.
(e)
Install housing on valve stem.
(f)
Push valve stem into housing and secure with upper spirolox when stem protrudes out of the top of housing.
(g)
Tighten clamp on boot.
(h)
Install cable assembly through bottom of drain valve assembly.
(i)
Where applicable, install cotter pin on valve stem.
(j)
Install spring(s) and washers as applicable over cable assembly.
(k)
Install cover assembly over cable assembly. Align all parts and push cover assembly into position and secure using nuts and washers. WARNING:
NOTE:
(l)
Cover assembly is spring loaded in the installed condition. Exercise care while removing to avoid possible injury.
On some drain valves, the cover assembly must be installed in the correct direction with respect to the housing assembly. Its orientation is important to provide the proper direction of the cable assembly.
Route cable assembly and install pulleys using clevis pins, washers, and cotter pins as required.
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(4)
Assembly of a timer assembly. There is no particular sequence that must be followed to assemble a timer assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general assembly sequence. The following special procedures, where applicable, should be followed during assembly. (a)
(5)
If printed circuit board assembly is being installed refer to applicable schematic diagram in CHECK for wire connections.
Assembly of a check valve assembly. There is no particular sequence that must be followed to disassemble a check valve assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general assembly sequence. The following special procedures, where applicable, should be followed during assembly. (a)
Some check valve assemblies have an upper cap that can be mounted at different directions in relation to the check valve body. Ensure the cap is installed correctly with respect to the body
(b)
When installing the mushroom valve on the body, pull the installation tail through the hole in the body, then trim the tail approximately 0.13 in. from bulb end. See Figure 16.
Mushroom Valve Installation Figure 13
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
(5)
Assembly of a liquid level transmitter. There is no particular sequence that must be followed to assemble a liquid level transmitter assembly. Reversing the breakdown order of the applicable IPL4620 Series manual may serve as a general assembly sequence.
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Monogram Systems MAINTENANCE MANUAL PN 4620 and 12300 Series
ILLUSTRATED PARTS LIST 1.
General A.
This section is provided in a separate IPL4620 series manual. Refer to INTRODUCTION, Table I for the cross-reference of a 4620 series or 12300 series toilet assembly to its applicable IPL4620 series manual.
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