FLUSHMATE 504 Series Replacement Tank Kit Instruction Manual

FLUSHMATE 504 Series Replacement Tank Kit

Product Information

The product is the Flushmate system, specifically the 503, 503-H, and 504 Series. It is a pressure-assist toilet system that requires a minimum operating pressure for proper functioning. The system includes various components such as the lower supply group with hose, supply shank with inlet screen, pressure regulator with back check, relief valve, upper supply group BU100505, air inducer cap with duckbill, vacuum breaker, and flush valve cartridge assembly. The product comes with a limited warranty provided by Flushmate.

It is important to note that the use of petroleum-based lubricants or cleaning products containing chlorine in the toilet tank and/or Flushmate vessel will void the warranty. The product should be installed according to applicable plumbing codes and using cold, potable water only.

Product Usage Instructions

Installation

1. Please follow the toilet manufacturer’s installation instructions for installing the fixture.
2. Ensure that the toilet has a minimum water supply line pressure. Refer to the manufacturer’s specifications for the minimum operating pressure for the fixture.
3. Before attaching the Flushmate system, flush the water supply lines.

Operation

• All pressure-assist toilets, including the Flushmate system, require sufficient pressure at the water supply line.
• Refer to the toilet manufacturer’s specifications for the minimum operating pressure for the fixture.

Important: Do not return to store where pur- chased. Please read the entire manual before attempting to make any adjustments or repairs.

Limited Warranty

Flushmate Limited Warranty Summary

Flushmate, LLC, (“Flushmate”), warrants each Flushmate Pressure Assisted System against defects in materials and workmanship. Flushmate’s limited warranty does not cover abuse, misuse, vandalism, or damage caused by Acts of God or other matters beyond Flushmate’s control, such as use of harmful chemicals, modifications to or faulty installation of the system, or improper or deficient plumbing. You can file a claim by email, telephone or regular mail by following the instructions found in the Limited Warranty which can be obtained at www.flushmate.com or by requesting a free copy by telephone at (800)-533-3460.

If you submit a valid claim, Flushmate at its discretion, will repair or replace your defective product, or provide a refund, as your exclusive remedy. This is only a general summary of Flushmate’s limited warranty so it  is important to note that the specific terms, conditions, restrictions, limitations and exclusions, including the duration of the warranty, are contained in the actual Flushmate Limited Warranty. In case of a conflict with the above summary, the complete warranty terms will prevail.

Minimum Operating Pressure By Series

• Minimum operating pressure by series for FLUSHMATE unit only. Max 80 psi

List of Components

List of Components for 503, 503-H and 504 Series:

1. Lower Supply Group w/Hose
   • (A) Supply Shank w/inlet screen
   • (B) Pressure Regulator w/Back Check
   • (C) Relief Valve
2. Upper Supply Group BU100505
   • (D) Air Inducer Cap w/duckbill
   • (E) Vacuum Breaker
3. Flush Valve Cartridge Assembly
   • (F) Actuator w/setscrew
4. FLUSHMATE® Tank
   • (G) Discharge Extension w/Drain
   • (H) Name Plate w/Serial Number
   • (I) Flush Rod

WARNING: To Prevent Injury:

• Read Installation Manual
• Read entire manual before performing any tasks.

Safety Precautions

Care should be taken when working on the Flushmate System. Surfaces can become wet, which may create a slip / fall hazard. Exposed tank bolts have sharp threads and may cause injury – avoid contact. Lifting the toilet tank (up to 45 Ibs./20.4 kgs) is required. If you are unable to lift the toilet tank contact Flushmate: 1.800.533.3460

Vessel Under Pressure

• Prior to servicing the Flushmate System, first completely CLOSE water supply stop and then flush toilet to release pressure from the Flushmate vessel. Failure to do so can result in injury or damage to the toilet tank and bowl.

NOTICE

• Use of petroleum based lubricants or cleaning products containing chlorine (household bleach, drop-in blocks or tablets, disinfectants) that are applied or inserted into the toilet tank and/or Flushmate vessel will void vour
• Flushmate Limited Warranty. When cleaning the exterior of the toilet, follow manufacturer’s recommendations.
• Install according to applicable plumbing code.
• Use cold, potable water only.

Installation

Please follow the toilet manufacturer’s installations instruction for installing the fixture. Note that the toilet requires a minimum water supply line pressure. See or refer to manufacturers’ specifications for minimum operating pressure for the fixture. Before attaching, you should always flush the water supply lines. After completing the installation, you are required to adjust the Cartridge Actuator (F). To adjust, make sure the water is turned on and the vessel is completely charged.

The Actuator needs to be set at the proper clearance, 1/8″ from either the Flush Rod or push button. To make this adjustment, hold the Actuator while loosening the Phillips setscrew in the center of the Actuator, and rotate the Actuator up (counterclockwise) or down (clockwise) until the proper clearance is obtained. See Figure 4 for clearance required for flush-handle fixture. Tighten setscrew after adjusting the Actuator.

Additional notes

• Water supply requirement: cold water, potable water system.
• You may be required to initially flush the toilet a few times to properly charge the system.
• Should a two piece fixture develop a leak between the tank and bowl, please refer to the fixture manufacturer’s installation instructions.
• Steps for Run-On Condition:
  1. Recheck the actuator adjustment described above
  2. Clean the Shank Inlet Screen ©(A) and check your water supply pressure – See Step 6
  3. Remove/Rinse/Reinstall the Flush Cartridge ® – See Step 2 for Cartridge Removal/Installation.

Operation

All pressure-assist toilets get their energy from the water supply line. It is important to have sufficient pressure at the supply. Refer to the toilet manufacturers’ specifications for minimum operating pressure for the fixture.

Step 1: Check Flush Cartridge 3

• Turn off water supply and flush toilet.
• Pour water onto top of cartridge (Fig. 1) and turn on water.
• Watch for air bubbles. Consistent flow of bubbles indicates cartridge needs to be replaced. No bubbles visible, move on to Step 4.

Step 2: Flush Cartridge 3 Installation

• Turn off water and flush the toilet.
• Use the handle end of pliers (Fig. 2) to unscrew the cartridge from the vessel.
• Drop in new cartridge and screw in until one female thread (Fig. 3) of vessel is showing.
• Turn on water. Continue to screw in cartridge slowly, 1/8 to 1/4 turn increments until water stops running into the bowl and tank pressurizes.

Step 3: Actuator 3 (F) Adjustment

• Start by loosening the setscrew in the center of the actuator. Adjust the height of the actuator by screwing it up or down.
• There should be a gap (Fig. 4) (about the thickness of a penny) between the rod and actuator when gently lifting the rod. When accomplished tighten the setscrew in the center of the actuator.

Step 4: Check Air Inducer 2 (D)

• Place several drops of water over hole on top of air inducer and flush toilet (Fig. 5). If drop is vacuumed in, move onto step 6. If not, air inducer needs to be cleaned.

Step 5: Clean Air Inducer 2 (D)

• Turn off water and flush toilet. Unscrew the cap of the air inducer (the smaller of the two caps) (Fig. 6).
• Pull the duckbill out from the cap and clean it by gently squeezing it (Fig. 7) between your fingers under a flow of water. Inspect the lips of the duckbill. If they are deformed, the duckbill needs to be replaced.
• Reassemble, insert the duckbill into the housing (Fig. 8) body and reinstall the cap finger tight.

Step 6: Clean Inlet Screen 2 (D)

• Clean the inlet screen by turning off the water supply, disconnecting the water supply line from the supply shank and removing the screen with a paper clip (Fig. 9).
• Clean screen (Fig. 10) and replace.

Other Points to Remember

1. Pressure-assist toilets get their energy from the water supply.
2. Refer to the toilet manufacturers’ specifications for minimum operating pressure for the fixture.
3. A blocked bowl or drain will affect the fixture’s performance. To check for this, pour 2 to 3 gallons of water into the bowl. If the bowl accumulates water in it, this would indicate that something is blocking the bowl/drain. If you need additional help, please contact the manufacturer of the flushing system, or do a word search on “pressure-assist toilets” on the web.

FLUSHMATE REPLACEMENT INSTRUCTIONS

Replacement Instructions for Two Piece Flushmate® Tanks

• Products: Two Piece Toilet
• Applications (M-101526)

Tools Required

• Large Adjustable Wrench for 3″ nut
  • (recommend Flushmate ST100100 3-in-1 wrench) 6″ Pliers
• Philips and Slotted screwdrivers

Instructions

1. Tum off water at the supply stop. Flush the toilet to relieve water and air pressure from the Flushmate® system. Disconnect water supply line from the supply shank and remove the lock nut that holds the supply shank in place. The supply shank protrudes from the bottom of the china tank on the left hand side.
2. If necessary, disconnect the Flushrod from the flush- handle linkage. Remove the screws that attach the Flushrod to the Flushmateand use them to attach the Flushrod to the new Flushmate®
3. Loosen the nuts on the bolts protruding from the underside of the toilet, below the china tank. These nuts should be loosened much like lug nuts on an automobile wheel; alternate between them instead of completely removing one at a time.
4. Once the nuts have been removed, lift the china tank straight up off of the bowl. Empty any residual water that may have accumulated in the china tank into the china bowl. Place the china tank down flat on its backside on a secure location.
5. Remove the “tank to bow* gasket (thick, spongy doughnut- type) from the Discharge Extension and unscrew large lock-nut on the bottom center of the china tank. A spanner wrench works well for this, but any tool that will spread to accommodate the 3” plastic locknut will work.
6. Slide the Flushmate® system out of the china tank.
7. Place new “tank to tank” gasket (flat rubber gasket with ribs on one side) on new Flushmate® with the ribs facing downward. Some “tank to tank” gaskets do not have ribs; installation of this gasket is universal. Slide the Flushmate® system into the china tank. It’s best to insert the supply shank into the china tank first and then the Flushmate® vessel.
8. Screw both lock-nuts onto the exposed threads (supply shank and discharge extension) on the bottom end of the china tank.
9. Place the “tank to bow* gasket onto the exposed discharge extension and reattach tank to bowl.
10. Attach brass washers and hex nuts to each bolt (making sure you put the washers on before the hex nuts) and tighten securely. When tightening the tank to bowl nuts, use the alternating method while putting downward pressure on each side as you tighten the nuts on that side. In effect, you will be rocking” the system in the direction of the nuts you are tightening. You must get the bolts tight enough to prevent any leakage (when flushed) between the tank and the bowl, but not so tight that you risk breaking the china.
11. Reattach water supply line to the supply shank and turn on the supply stop. Wait for Flushmate® to set up (fill with water and stop “cycling” and flush the toilet. If the Flushmate® doesn’t set up and water continues to run through it, you will need to adjust the cartridge and perhaps the actuator cap. See the owners manual for adjustment or visit flushmate.com.

Replacement Instructions for One Piece Flushmate® Tanks

• Products: One Piece Toilet Applications (M-102540 Models)

Tools Required

• Large Adjustable Wrench for 3″ nut
  • (recommend Flushmate ST100100 3-in-1 wrench) 6″ Pliers
• Philips and Slotted screwdrivers

Instructions

1. Tum off water at the supply stop. Flush the toilet to relieve water and air pressure from the Flushmate® tank. Disconnect water supply line from the supply shank and remove the lock nut that holds the supply shank in place. The supply shank protrudes from the bottom of the china tank on the left hand side.
2. Loosen the nuts on the bolts protruding from the underside of the toilet, below the china tank. These nuts should be loosened much like lug nuts on an automobile wheel; alternate between them instead of completely removing one at a time.
3. Once the nuts have been removed, lift the Flushmate® tank straight up out of the toilet tank. Empty any residual water that may have accumulated in the china tank and then set it down flat on the backside with the front of the china tank facing the ceiling.
4. If necessary, disconnect the Flushrod from the flush- handle linkage. Remove the screws that attach the Flushrod to the Flushmate® and use them to attach the Flushrod to the new Flushmate.
5. Remove rubber washers from the bolts and install them on the new Flushmate.
6. If the “tank to tank” gasket is attached to the Flushmate® remove it and place it on the new Flushmate®. Contact the fixture manufacturer for replacement if required.
   • If equipped with a Drain Valve Assembly
   • If the Drain Valve Assembly is intact and not broken you can proceed to the next step.
   • If the Drain Valve Assembly is broken you will need to replace it.
   1. At the inside bottom of the tank you will see a small the Drain Valve Assembly.
   2. Either pull it out or unthread it based on your fixture manufacturer. If you have to unthread it out of the china tank you will need to put your fingers inside the large discharge outlet in the china tank and hold the locknut, while unthreading the Drain Valve Assembly.
   3. Once you remove the Drain Valve Assembly, make sure that the small white plastic ball is intact. If the ball is missing you will need to remove it from the toilet bowl.
   4. To remove this ball, you will need to remove the from the floor, gently lay the toilet on the backside and gently rock the toilet back and fourth (from side to side) until the ball rolls out.
   5. Next you will need to reinstall the toilet back on the floor.
   6. Then install the new Drain Valve Assembly, do the reverse as vol did to remove
7. Reinstall the Flushmate® into china tank, by aligning bolts through the holes and the threaded shank through the larger hole on the left-hand side.
8. Attach new brass washers and brass hex nuts to each bolt making sure you put the washers on before the hex nuts) and tighten securely. When tightening the tank to bowl nuts, use the alternating method while putting downward pressure on each side as you tighten the nuts on that side. In effect, you will be “rocking” the tank in the direction of the nuts you are tightening. You must get the bolts tight enough to prevent any leakage When flushed) between the tank and the bowl, but not so tight that you risk breaking, the china.
9. Reattach water supply line to the supply shank and turn on the supply stop. Wait for Flushmate® to set up (fill with water and stop “cycling”) and flush the toilet. If the Flushmate® doesn’t setup and water continues to run through it, you will need to adjust the cartridge and perhaps the actuator cap. See the owners manual for adjustment of visit flushmate.com.

Winterizing

1. Turn off the water supply valve and flush the toilet to relieve the pressure.
2. Place a bucket under the lower Supply Shank (A) and disconnect the water supply line, allowing the water to drain into the bucket.
3. Push down on the Actuator and pull it up momentarily to allow air into the vessel.
4. Follow the fixturo manufacturor’s instructions for winterizing the bowl.
5. Do not put antifreeze or any other chemical agents in the china holding tank or in the FLUSHMATE® Tank.

Points to Remember

• When replacing components on the FLUSHMATE® Flushometer-Tank System, make certain that the water supply valve is turned off and the toilet has been flushed to relieve pressure in the FLUSHMATE® tank.
• WARNING: USE OF PETROLEUM-BASED LUBRICANTS OR CORROSIVE CLEANING PRODUCTS CONTAINING CHLORINE, SUCH AS HOUSEHOLD BLEACH, DROP-IN BLOCKS OR TABLETS, OR DISINFECTANTS THAT ARE APPLIED INSIDE THE CHINA HOLDING TANK WILL VOID YOUR FLUSHMATE® WARRANTY.
• Water supply requirement: cold water, potable water system.
• The Flush Valve Cartridge can be removed by inserting the handles of a pair of pliers into the top of the Flush Valve Cartridge and turning counterclockwise.
• With each flush, a small amount of water may be emitted from the upper supply group. A drain at the base of th FLUSHMATE® system will eliminate most of this water. Depending on usage, you may see some residual water (less than 1″) in the china holding tank. This is a normal occurrence.
• Your water pressure is adequate if your water supply line will yield one or more gallons of water within thirty (30) seconds.
• Replacement parts are readily available by contacting Consumer Services at 800-533-3460 or by visiting the “Where to Buy section of our website, flushmate.com, or purchase online at eflushmate.com.

If you would like additional information or require technical assistance, please contact FLUSHMATE® Consumer Services at 800-533-3460, or visit our website, www.flushmate.com. For faster service, please be prepared to provide the serial number and date of installation of your FLUSHMATE® system. For support outside the United States, visit our local contact website at flushmate.com.

Additional service manuals and a variety of other helpful information is available online at flushmate.com
If you have any further questions, please feel free to contact Consumer Services at 800-533-3460 or email [email protected]

Product Registration

It is very important to register your product after installation. Product registration al- lows Flushmate to deliver the most current product information available

• Owner’s name: …………………………..

• Telephone: …………………………..
  E-mail: …………………………..

• Owner’s address: …………………………..

• City: …………………………..

• State: …………………………..

• Zip: …………………………..

• Date purchased: …………………………..

• Date installed: …………………………..

• Serial number: …………………………..

• Model number: …………………………..

Both numbers located on the label on top of the Flushmate vessel.

• Toilet name (located on bowl)

Mail-in or register online: flushmate.com

• It is very important to register your product after installation.
• Product registration allows Flushmate to deliver the most current product information available.
• Mail-in or register online: www.flushmate.com
• 30075 Research Drive, New Hudson, MI 48165-8548
• www.flushmate.com

Flushmate

• 30075 Research Drive New Hudson, MI 48165-8548 USA

Installation Date: ………………………
Serial Number: ………………………

Scan using your smartphone to view troubleshooting videos or visit: flushmate.com/resources

References

• Sloan Flushmate Genuine Parts Store - Flushmate Repair Parts
• Flushmate® | Power Flush, Pressure Assist Toilet Systems
• Sloan Flushmate Genuine Parts Store - Flushmate Repair Parts
• Flushmate® | Power Flush, Pressure Assist Toilet Systems

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