Toilet Drain Valve Replacement – 2017-2019 Prevost X3

SEOCONTENT-START

<QF7720959 rev 5>
Writer: mg
Instruction Sheet IS-18158
TOILET DRAIN VALVE REPLACEMENT
First Release
06-27-2019
MATERIAL
Kit # 401294 includes the following parts:
Part No.
Description
Qty
900195
VALVE, TOILET DRAIN 3 INCH
1
401296
ADAPTER
1
5000310
SCR CAP HEX SS NSS M6X1 X 40
4
5001833
WSH BEL SPR SS 301 6.65X17.4X1.27 (M6 x 1/4)
4
IS-18158
INSTRUCTION SHEET (EN)
1
FI-18158
INSTRUCTION SHEET (FR)
1
Other material that may be required:
Part No.
Description
Qty
680098
LOCTITE 567 TEFLON 250ML
1
684685
GLUE SIMSON ISR 70-03 BLACK, CARTRIDGE
1
N8907092
LOCTITE 7649 (SPRAY)
1
NOTE
Material can be obtained through regular channels.
PROCEDURE
DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to your local procedure for detailed information regarding the control of hazardous energy.
IS-18158
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Writer: mg <QF7720959 rev 5>
PART 1: TOILET PREPARATION
1. Remove the toilet drain pipe from the vehicle.
– Flush and rinse the toilet tank.
NOTE
Ideally, this operation is done a few hours before the valve replacement. The aim is to minimize the presence of dripping liquid at the toilet valve flange that could compromise sealing.
– Loosen upper and lower pipe hose clamps.
– Disconnect the overflow tube.
– Remove the drain pipe.
IS-18158
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Writer: mg <QF7720959 rev 5>
2. Remove the old toilet drain valve from the vehicle.
– Unscrew the valve from the toilet flange (flange may be tight, apply localized but moderate heat with a heat gun as required).
NOTE
Cut some insulating material around the toilet flange to expose a few more threads and ease cleaning as shown.
3. Clean the toilet flange threads.
– Clean the flange thread from lose crust of rust and adhesive using a suitable (non-aqueous) cleaner degreaser (wipe off the excess).
– Using a brass wire wheel brush mounted on a high speed rotary tool, thoroughly clean the flange threads from the remaining rust (clean to shiny bare metal).
CAUTION
Wear appropriate eyes protection.
– Complete the cleaning using a residue free cleaner (break cleaner or equivalent) on the threads.
IS-18158
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Writer: mg <QF7720959 rev 5>
PART 2: VALVE PREPARATION
1. Remove and discard the top adapter part of the valve (with inner threads).
– Remove the four bolts holding the top and bottom adapters to the valve.
– Discard the top adapter (with inner threads) and the bolts (do not discard rubber seal).
– Clean the top of the valve body (where the top adapter was bolted) with brake cleaner followed by anti-silicone; surface must be free of assembly oil film.
2. Clean the new stainless adapter flange.
– Clean the bottom flange of the 401296 stainless adapter with brake cleaner followed by anti-silicone, surface must be free of contaminants.
– Also clean the rubber joint (oil free) and install it (dry) on the flange.
IS-18158
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Writer: mg <QF7720959 rev 5>
3. Apply adhesive to the valve upper part perimeter.
– Apply heat to the valve inner perimeter with a heat gun (try to minimise heating of the metal sliding “gate”). The heated area must be hot but must not distort (melt); the plastic will start to look “wet” when the melting temperature is about to be reached.
NOTE
Go slowly with the heat gun set at a medium temperature setting. Start at a safe distance from the valve body and adjust as necessary.
In any case, do not allow the plastic to reach the melting/distorting point.
– Apply a bead of black Simson 70-03 adhesive at the valve perimeter (heated area). Adhesive must be applied within 30 min. or the area will have to be re-heated.
4. Reassemble the toilet valve.
– Install the stainless adapter (and rubber joint) on top of the valve body. Align bolt holes as much as possible and press slightly to spread the Simson adhesive.
– Reassemble the valve using the supplied 5000310 hex screws and 5001833 Belleville washers (the stainless adapter is threaded).
NOTE
Make sure that the lower adapter rubber joint is correctly reinstalled.
– Torque all screws to 40 lb-in (4.5Nm) in a cross pattern.
– Wipe off any adhesive excess.
– Activate the valve a few times to ensure proper function.
IS-18158
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Writer: mg <QF7720959 rev 5>
PART 3: TOILET VALVE INSTALLATION
1. Trial fit the installation of the valve to the flange without any sealant.
– Make sure that once torqued in place (pipe threads), the valve handle is pointing straight (facing the operator).
– If the handle is not straight, try others starting positions 45 deg. apart until a correct torqued alignment is achieved and take note of it for final installation.
NOTE
Do not over torque or back up the valve to achieve correct alignment.
Mark the starting point of the valve vs. the flange on the valve body as necessary for future refer-ence.
– Remove the valve from the toilet flange.
2. Apply primer to the threads.
– Apply a coat of Loctite 7649 primer/activator to the toilet flange and to the stainless adaptor threads (protect rubber joint).
– Allow the solvent in the primer time to evaporate until the surfaces are completely dry (+/- 15 min.).
IS-18158
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Writer: mg <QF7720959 rev 5>
3. Apply sealant to the threads.
– Apply a coat of Loctite 567 PST thread sealant to the toilet flange.
– Also apply a coat of thread sealant to the threads of the stainless adaptor (protect rubber joint).
NOTE
Push the sealer into the threads.
4. Screw the valve to the flange.
– Screw the flange until a fairly tight connection is achieved and the valve is pointing straight at the operator.
NOTE
Use the reference mark as required (see step 1 above).
CAUTION
Do not over torque or back up the valve to achieve correct alignment.
IS-18158
Page 8 / 8
Writer: mg <QF7720959 rev 5>
5. Reinstall the toilet drain pipe and overflow tube.
– Reinstall the drain pipe and related hose clamps. Do not apply sealant at the lower valve flange.
– Reconnect the overflow tube and tighten hose clamp.
6. Refill the tank and check for leak.
NOTE
For maximum pressure resistance; Before filling the tank, allow the Loctite 567 to cure 24 hours.
PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)