Installation of the Flush Valve

TASK 38-31-57-400-001-A
Installation of the Flush Valve

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

WARNING: DO NOT DO WORK ON THE TOILET WASTE SYSTEM AND THE POTABLE WATER SYSTEM AT THE SAME TIME. THIS WILL PREVENT CONTAMINATION OF THE POTABLE WATER SYSTEM. SUCH CONTAMINATION CAN BE DANGEROUS TO HEALTH.

WARNING: ALWAYS USE RUBBER GLOVES WHEN YOU DO WORK:

ON THE TOILET WASTE SYSTEM, OR
ON PARTS THAT HAVE CONTAMINATION FROM THE WASTE SYSTEM.

WHEN YOU COMPLETE THE WORK PROCEDURE, CLEAN YOUR HANDS WITH SOAP AND WATER. THIS WILL PREVENT INFECTION (TOILET WASTE IS DANGEROUS FOR HEALTH).

NOTE: The installation of the flush valve in lavatories is the same.

ZONE: 200

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	Torque wrench: range to between 35 and 25 lbf.in (0.40 and 0.28 m.daN )
No specific	Torque wrench: range to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03FAB1)	Mineral Oil base Grease-- Vaseline or Petrolatum -
No specific	CABLE TIE

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
200	UPPER HALF FUSELAGE

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
17	PACKING	AIPC 38-31-01-47-080
2	PACKING	AIPC 38-31-01-47-080
7	PACKING	AIPC 38-31-01-47-080
17	PACKING	AIPC 38-31-01-48-080
7	PACKING	AIPC 38-31-01-48-080
7	PACKING	AIPC 38-31-04-07-060
17	PACKING	AIPC 38-31-04-07-070
17	PACKING	AIPC 38-31-04-08-080
17	PACKING	AIPC 38-31-04-09-080
17	PACKING	AIPC 38-31-04-10-040
17	PACKING	AIPC 38-31-04-10-060
17	PACKING	AIPC 38-31-04-10-080
2	PACKING	AIPC 38-31-04-10-090
17	PACKING	AIPC 38-31-04-12-080
17	PACKING	AIPC 38-31-04-19-080
18	PACKING	AIPC 38-31-41-30-070
8	PACKING	AIPC 38-31-41-30-140
14	PACKING	AIPC 38-31-41-30-160
2	PACKING	AIPC 38-31-41-30-210
8	PACKING	AIPC 38-31-41-40-140
14	PACKING	AIPC 38-31-41-40-160
24	O-RING	AIPC 38-31-41-40-170
5	PACKING	AIPC 38-31-41-40-180
2	PACKING	AIPC 38-31-41-40-190
8	PACKING	AIPC 38-31-41-40-200
2	PACKING	AIPC 38-31-41-40-210
17	PACKING	AIPC 38-31-81-40-050
7	PACKING	AIPC 38-31-81-40-050
17	PACKING	AIPC 38-31-84-01-050
7	PACKING	AIPC 38-31-84-01-050
7	PACKING	AIPC 38-31-84-02-030
17	PACKING	AIPC 38-31-84-10-050
7	PACKING	AIPC 38-31-84-10-050
7	PACKING	AIPC 38-31-84-11-030
7	PACKING	AIPC 38-31-84-15-050
7	PACKING	AIPC 38-31-84-16-050
7	PACKING	AIPC 38-31-84-20-050
7	PACKING	AIPC 38-31-84-22-060
7	PACKING	AIPC 38-31-84-25-050
7	PACKING	AIPC 38-31-84-26-060

E. Referenced Information

REFERENCE	DESIGNATION
TASK 24-42-00-861-001-A	Energize the Ground Service Network from the External Power
TASK 24-42-00-862-001-A	De-energize the Ground Service Network Supplied from the External Power
TASK 25-45-22-000-001-A	Removal of the Toilet Shroud and the Seat
TASK 25-45-22-000-802-A	Removal of the Toilet Shroud of the Space Flex Lavatory
TASK 25-45-22-400-001-A	Installation of the Toilet Shroud and the Seat
TASK 25-45-22-400-802-A	Installation of the Toilet Shroud of the Space Flex Lavatory
TASK 38-10-00-614-001-A	Pressurization of the Potable Water System from a Ground Air Supply
TASK 38-10-00-614-002-A	Depressurization of the Potable Water System
TASK 38-10-00-614-003-A	Pressurization of the Potable Water System with the Compressor
TASK 38-31-00-710-009-A	Operational Test of the Toilet Unit
TASK 38-31-00-790-002-A	Leak Test of the Vacuum Toilet System (VTS)
TASK 38-31-00-790-003-A	Leak Test of the Vacuum Toilet System
TASK 38-31-55-400-001-A	Installation of the Water Valve
Flush Valve Assembly ** ON A/C NOT FOR ALL
Flush Valve Assembly ** ON A/C NOT FOR ALL
Flush Valve Assembly ** ON A/C NOT FOR ALL
Clamp Installation Requirements

3. Job Set-up
Subtask 38-31-57-860-050-C

A. Aircraft Maintenance Configuration
(1) Make sure that the ground service network is energized
(Ref. AMM TASK 24-42-00-861-001).
(2) Make sure that you do the depressurization of the potable water system (Ref. AMM TASK 38-10-00-614-002).
(3) Make sure that you have access to the lavatory.
(4) Make sure that the sanitary cabinet door is open.
(5) Make sure that the potable-water shutoff valve is closed.
(6) Make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to open the potable-water shutoff valve.
(7) Make sure that the toilet shroud is removed (Ref. AMM TASK 25-45-22-000-001) (Ref. AMM TASK 25-45-22-000-802).

Subtask 38-31-57-865-060-A

B. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACUUM-SYS	35MG	A06
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACUUM-GEN	33MG	A08
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-E	34MG	A04
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-D	39MG	A03
** ON A/C ALL
2001VU	VACU TOIL SYS-LAV PWR-A	32MG	A01
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACU-SYS	35MG	A06
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACU-GEN	33MG	A08
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-G	34MG	A04
2001VU	VACU TOIL SYS-LAV PWR-F	39MG	A03
2001VU	VACU TOIL SYS-LAV PWR-D	45MG	A02
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-L	45MG	A02
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-L	23MG	A05
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-M	34MG	A04

4. Procedure
Subtask 38-31-57-420-050-E ** ON A/C NOT FOR ALL

WARNING: ALWAYS WEAR RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHES WHEN YOU DO THIS TASK.

A. Installation of the Flush Valve Assembly

Clamp Installation Requirements ** ON A/C NOT FOR ALL

(1) Clean the component interfaces and the adjacent area.
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Install the flush valve assembly (13) in the bowl elbow (15) as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Select the applicable new packing (14):

(c) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the packing (14).
(d) Put the packing (14) in its correct installation position.
(e) Put the flush valve assembly (13) in its correct installation position.
(f) Install the washers (17) and the nuts (16).
(g) TORQUE the nuts (16) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(h) Connect the vent tube (20).
(i) Install the washer (9) and the nut (10) in the housing support bracket (11).
(j) TORQUE the nut (10) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(4) Install the outlet elbow (5) in the flush valve assembly (13) as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Select the applicable new packing (8):

(c) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the packing (8).
(d) Put the packing (8) in its correct installation position.
(e) Put the outlet elbow (5) with the swivel plate (21) in their correct installation positions.
(f) Install the bolts (12), the washers (7) and the nuts (6).
(g) TORQUE the nuts (6) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(5) Connect the outlet elbow (5) to the waste water line (1) as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Select the applicable new packing (2):

(c) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the packings (2).
(d) Put the packings (2) in their correct installation positions.
(e) Put the sleeve (3) in position.
(f) Install the clamp (4) and lock it.
(g) Make sure that the clamp (4) is locked correctly:

The axial adjustment is not more than 6.35 mm (0.25 in.).
The angular misalignment is not more than +/- 4 degrees in all the directions around the centerline.

(6) If the water valve is removed, install it (Ref. AMM TASK 38-31-55-400-001).
(7) Connect the electrical connectors as follows:
(a) Remove the CAP-BLANKING from each electrical connector and receptacle.

CAUTION: MAKE SURE THAT THE ELECTRICAL CONNECTORS ARE CLEAN BEFORE YOU DISCONNECT OR CONNECT THEM. CONTAMINATION ON THE ELECTRICAL CONNECTORS CAN CAUSE DAMAGE TO EQUIPMENT.

CAUTION: WHEN YOU CONNECT THE ELECTRICAL CONNECTORS, MAKE SURE THAT YOU CONNECT EACH PLUG TO THE CORRECT RECEPTACLE (USE THE IDENTIFICATION MARKS).

(b) Connect the electrical connectors (18) and (19).

Subtask 38-31-57-420-050-F ** ON A/C NOT FOR ALL

A. Installation of the Flush Valve Assembly

Clamp Installation Requirements ** ON A/C NOT FOR ALL

(1) Clean the component interfaces and the adjacent area.
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Put the flush valve assembly (25) in its installation position.
(4) Engage the flush valve assembly (25) with the inlet elbow (2):
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the new AIPC 38-31-41-40-180 PACKING (5).
(c) Put the packing (5) and the inlet elbow (2) in their installation positions.
(d) Install the washers (4) and the nuts (3).
(e) TORQUE the nuts (3) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(5) Installation of the vertical support (7):
(a) Put the bracket (13) and the vertical support (7) in their installation positions.
(b) Install the bolts (12), the washers (8) and the nuts (9).
(c) TORQUE the nuts (9) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(d) Install the washers (10) and the nuts (6).
(e) Tighten the nuts (6).
(6) Installation of the outlet elbow (21) or (28):
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the new AIPC 38-31-41-40-170 O-RING (24).
(c) Put the O-ring (24) and the outlet elbow (21) or (28) in their installation positions.
(d) Put the swivel plate (16) in its installation position.
(e) Install the bolts (11), the washers (14) and the nuts (15).
(f) Tighten the nuts (15).
(g) Install the washers (23) and the nuts (22).
(h) TORQUE the nuts (22) to between 0.17 and 0.14 m.daN (15.04 and 12.39 lbf.in )

.
(7) Remove the PLUG-BLANKING from each disconnected line end.
(8) Select the applicable new packings (17):
(9) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the new packings (17).
(10) Put the packings (17) in their installation positions and install the sleeve (19) and the clamp (18).
(11) Make sure that the clamp (18) is locked correctly:

The axial adjustment is not more than 6.35 mm (0.25 in.)
The angular misalignment is not more than +/- 4 deg. in all the directions around the centerline.

(12) Install the new CABLE TIE (26) on the vent tube (27).
(13) Remove the CAP-BLANKING from each electrical connector and receptacle.

CAUTION: MAKE SURE THAT THE ELECTRICAL CONNECTORS ARE CLEAN BEFORE YOU DISCONNECT OR CONNECT THEM. CONTAMINATION ON THE ELECTRICAL CONNECTORS CAN CAUSE DAMAGE TO EQUIPMENT.

(14) Connect the electrical connector (1).
(15) Install the water valve (Ref. AMM TASK 38-31-55-400-001).

Subtask 38-31-57-420-050-G ** ON A/C NOT FOR ALL

WARNING: ALWAYS WEAR RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHES WHEN YOU DO THIS TASK.

A. Installation of the Flush Valve Assembly

Clamp Installation Requirements ** ON A/C NOT FOR ALL

(1) Clean the component interfaces and the adjacent area.
(2) Do an inspection of the component interfaces and the adjacent area.
(3) Install the flush valve assembly (6) as follows:
(a) Put the flush valve assembly (6) and the inlet elbow (10) in their correct installation positions at the same time.
(b) Make sure that the guiding pin (2) of the flush valve assembly (6) is installed in the grommet (4).
(c) Install the quick-release fasteners (3) in the flush valve assembly (6).
(4) Connect the inlet elbow (10) to the toilet bowl (11) as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Connect the inlet elbow (10).
(c) Push the cam levers (12) to the closed position.
(d) Make sure that the locking pins (13) are fully out.
(5) Install the outlet elbow (16) in the flush valve assembly (6) as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on a new AIPC 38-31-41-30-070 PACKING (18).
(c) Put the packing (18) in its correct installation position.
(d) Put the outlet elbow (16) and the swivel plate (17) in their correct installation positions at the same time.
(e) Install the washers (14) and the nuts (15).
(f) TORQUE the nuts (15) to between 35 and 25 lbf.in (0.40 and 0.28 m.daN )

.
(6) Connect the outlet elbow (16) to the waste water system as follows:
(a) Remove the PLUG-BLANKING from each disconnected line end.
(b) Select the applicable new packings (7):
(c) Apply a thin layer of Mineral Oil base Grease-- Vaseline or Petrolatum - (Material No.03FAB1) on the new packings (7).
(d) Put the packings (7) in their correct installation positions and install the sleeve (8) and the clamp (9).
(e) Make sure that the clamp (9) is locked correctly:

The axial adjustment is not more than 6.35 mm (0.25 in.).
The angular misalignment is not more than +/- 4 degrees in all directions around the centerline.

(7) If the water valve is removed, install it (Ref. AMM TASK 38-31-55-400-001).
(8) Connect the electrical connectors as follows:
(a) Remove the CAP-BLANKING from each electrical connector and receptacle.

CAUTION: MAKE SURE THAT THE ELECTRICAL CONNECTORS ARE CLEAN BEFORE YOU DISCONNECT OR CONNECT THEM. CONTAMINATION ON THE ELECTRICAL CONNECTORS CAN CAUSE DAMAGE TO EQUIPMENT.

CAUTION: WHEN YOU CONNECT THE ELECTRICAL CONNECTORS, MAKE SURE THAT YOU CONNECT EACH PLUG TO THE CORRECT RECEPTACLE (USE THE IDENTIFICATION MARKS).

(b) Connect the electrical connectors (5) and (1).

Subtask 38-31-57-865-061-A

B. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACUUM-SYS	35MG	A06
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACUUM-GEN	33MG	A08
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-E	34MG	A04
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-D	39MG	A03
** ON A/C ALL
2001VU	VACU TOIL SYS-LAV PWR-A	32MG	A01
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACU-SYS	35MG	A06
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-VACU-GEN	33MG	A08
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-G	34MG	A04
2001VU	VACU TOIL SYS-LAV PWR-F	39MG	A03
2001VU	VACU TOIL SYS-LAV PWR-D	45MG	A02
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-L	45MG	A02
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-L	23MG	A05
** ON A/C NOT FOR ALL
2001VU	VACU TOIL SYS-LAV PWR-M	34MG	A04

Subtask 38-31-57-790-051-A

C. Leak Test
(1) Remove the WARNING NOTICE(S) related to the potable-water shutoff valve.
(2) Open the potable-water shutoff valve.
(3) Pressurize the potable water system (Ref. AMM TASK 38-10-00-614-001) or (Ref. AMM TASK 38-10-00-614-003).
(4) Do the leak test of the vacuum toilet system (Ref. AMM TASK 38-31-00-790-002) or (Ref. AMM TASK 38-31-00-790-003).
(5) Record the results of the test.
(6) Compare the results of the test before the removal and after the installation.

NOTE: The difference between the tests is not more than 10% of the results made before the removal.

Subtask 38-31-57-710-050-A

D. Operational Test
(1) Operate the toilet assembly and make sure that it flushes correctly (Ref. AMM TASK 38-31-00-710-009).

5. Close-up
Subtask 38-31-57-410-050-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the toilet shroud (Ref. AMM TASK 25-45-22-400-001) (Ref. AMM TASK 25-45-22-400-802).
(3) Close the sanitary cabinet door.
(4) Close the lavatory door.

Subtask 38-31-57-862-050-A

B. De-energize the ground service network
(Ref. AMM TASK 24-42-00-862-001).

[Rev.10 from 2021] 2026.04.01 01:20:35 UTC