The Flushmate 503 Series is a pressure-assist toilet system designed to deliver reliable, high-performance flushing with water efficiency. It is commonly used in residential and commercial settings where durability and efficiency are critical. This guide provides a detailed, step-by-step overview of the installation and setup process, based on the official Flushmate user manual and technical instructions provided by the manufacturer.
The Flushmate 503 Series Pressure-Assist Systems are engineered to optimize water pressure and air compression for enhanced flushing performance. Designed with a 1.6 gallons per flush (6 liters per flush) water rating, these systems are ideal for users seeking a balance between water conservation and powerful flushing. The installation process involves replacing the existing Flushmate system within a toilet tank, and it is typically completed within an hour by someone with basic plumbing skills.
This guide draws from the official Flushmate installation and operation manual to outline the critical steps, precautions, and tools required for a successful installation. It includes guidance on winterizing the system, troubleshooting common issues, and understanding the technical specifications necessary for proper operation.
Key Components of the Flushmate 503 System
The Flushmate 503 system includes several critical components that work together to ensure efficient and effective operation. A detailed understanding of these parts is essential for a successful installation.
- Flush Valve Cartridge: This component controls the release of water and air during the flushing process. It is adjustable and requires careful handling to ensure optimal performance.
- Actuator: The handle or lever used to initiate a flush. It is connected to the flush valve cartridge and must be properly aligned and secured.
- Cartridge Body - Flushmate Vessel: This is the main housing unit of the system. It contains the mechanism that pressurizes the water and air to create the flush.
- Label and Serial Number: Found on the vessel, these are used for identification and warranty purposes.
- Discharge Extension (with Drain): Connects the vessel to the toilet tank and allows for water to flow out during the flush.
- Lower Supply Group + Hose: These components manage the incoming water supply to the system.
- Supply Shank: Connects the water line to the system.
- Inlet Screen: Filters the incoming water to prevent clogging.
- Pressure Regulator, Back Check, and Pressure Relief Valve: These ensure that the system maintains safe and consistent pressure levels.
- Upper Supply Group + Hose: Manages the upper water flow and includes a vacuum breaker to prevent siphoning.
- Air Inducer Cap: Helps in drawing air into the system, contributing to the pressure-assist function.
- Duckbill: A check valve that prevents water from flowing back into the vessel.
- Upper Supply Body with Vacuum Breaker: Ensures safe operation by preventing siphoning.
- Gaskets and Locknuts: Used to seal and secure various components of the system.
Each component plays a vital role in the system’s operation and must be handled with care during installation to avoid damage or improper function.
Pre-Installation Considerations
Before beginning the installation process, it is essential to review the technical requirements and prepare the work area to ensure a smooth and safe installation.
Water Pressure and Flow Requirements
The Flushmate 503 system requires specific water pressure and flow rates to function correctly:
- Minimum Operating Pressure: 20 psi (137.9 kPa)
- Maximum Operating Pressure: 80 psi (551.6 kPa)
- Minimum Water Flow Rate: 1 gallon (3.79 liters) in 30 seconds
These parameters are critical for the system to generate sufficient pressure for an effective flush. If the water supply does not meet these requirements, the system may underperform or fail to operate correctly.
Water Supply Specifications
The system is designed to use cold, potable water only. The use of non-potable water or hot water can lead to system damage and may void the limited warranty. Users should ensure that the water supply meets these criteria before installation.
Safety Precautions
Safety is a top priority during installation. The following precautions should be taken:
- Avoid Contact with Exposed Tank Bolts: These have sharp threads and may cause injury.
- Lifting the Toilet Tank: The tank may weigh up to 45 lbs (20.4 kg). If assistance is needed, contact Flushmate at 1-800-533-3460.
- Surfaces May Become Wet: This can create a slip or fall hazard. A towel should be used to clean up any excess water.
- Release Pressure Before Servicing: Always close the water supply stop and flush the toilet to release pressure from the system. Failure to do so can result in injury or damage to the toilet.
Tools and Accessories
The following tools and accessories are recommended for installation:
- 4-in-1 Tool: Includes a Phillips screwdriver and a nut driver (1/4 inch).
- 3-in-1 Wrench: Used for adjusting the flush valve cartridge.
- Optional Accessories: These include an AP300503 Handle Replacement Kit and an ST300500 Tool Kit.
Users should ensure that all tools and parts are available before beginning the installation process.
Step-by-Step Installation Instructions
The installation process for the Flushmate 503 system can be completed in approximately 45 minutes by following these steps.
Step 1: Prepare the Work Area
Before beginning the installation, ensure that the work area is clear and dry. Gather all necessary tools and components and read through the entire manual to understand the sequence of tasks.
Step 2: Turn Off Water Supply
Close the water supply stop valve and flush the toilet to release pressure from the system. This step is critical to avoid injury or damage during installation.
Step 3: Remove the Old Flushmate System
- Remove the Tank to Bowl Gasket: This gasket is located on the discharge extension and should be discarded after removal.
- Loosen and Remove the Discharge Locknut: Use the 4-in-1 tool to loosen and remove the locknut. Depending on the tank bolt configuration, you may need to reposition the toilet tank for better access.
- Slide the Existing Flushmate System Out: Carefully remove the old system from the toilet tank and dispose of it in accordance with local waste handling procedures.
Step 4: Install the New Flushmate System
- Place the New Tank to Tank Gasket: Install the new gasket on the discharge extension with the flat side facing the vessel.
- Align the Flushmate Vessel: Position the vessel as shown in the manual and ensure that it is aligned correctly.
- Release and Remove the Lower Supply Group: Gently wiggle and pull the lower supply group from the vessel’s mounting post.
- Guide the Supply Shank Through the Tank: Hold the supply shank in place and thread on the supply shank locknut by hand.
- Insert the New Flushmate System: Guide the discharge extension through the center opening of the tank. Hold the vessel in place and hand tighten the discharge extension locknut. Be careful not to cross-thread the locknut.
Step 5: Secure the System
- Tighten the Tank Bolts: Use the 4-in-1 tool to tighten the tank bolts. Some toilets may require the removal of rubber spacers between the tank and bowl during this process.
- Secure the Actuator: Hold the actuator in place and tighten the set screw using the 4-in-1 tool.
Step 6: Adjust the System
Newly installed systems often require minor adjustments:
- Ensure Water Supply Stop is Completely Open
- Loosen the Set Screw: Use the 4-in-1 tool to turn the set screw counter-clockwise approximately 4 rotations.
- Unscrew and Remove the Actuator: Set it aside for reinstallation.
- Adjust the Flush Valve Cartridge: Use the 3-in-1 wrench to turn the cartridge counter-clockwise until only one black thread of the vessel is showing. Then turn the cartridge clockwise ¼ turn and listen for the water to stop running.
Repeat this process as needed, waiting 30 seconds between each turn, until the water stops running. Flush the toilet twice, waiting one minute between flushes, to test the system.
If the water continues to run after two unsuccessful attempts, contact Flushmate at 800-533-3460.
Troubleshooting Common Issues
During or after installation, users may encounter common issues that can be resolved with the following steps:
Water Continuing to Run
This issue can often be resolved by adjusting the flush valve cartridge:
- Loosen the Set Screw: Use the 4-in-1 tool to turn the set screw counter-clockwise.
- Adjust the Cartridge: Use the 3-in-1 wrench to turn the cartridge in small increments until the water stops running.
- Test the System: Flush the toilet twice, waiting one minute between flushes, to confirm the issue is resolved.
Winterizing the System
If the toilet is located in an area with freezing temperatures, it is essential to winterize the system to prevent damage:
- Turn Off Water Supply
- Release Pressure: Flush the toilet to release pressure from the system.
- Drain Water: Disconnect the water supply line and allow the water to drain into a bucket.
- Push and Hold the Actuator Down: Hold for 5 seconds, then pull up and hold for 5 seconds to allow for residual water drainage and air entry.
- Sponge Out Water: Remove any additional water from the tank with a sponge.
- Follow Manufacturer Instructions: Consult the toilet manufacturer’s winterizing guidelines for additional steps.
Failure to follow these winterizing steps can result in damage to the system and may void the limited warranty.
Maintenance and Warranty Information
Proper maintenance is essential for the long-term performance of the Flushmate 503 system. Users should avoid using petroleum-based lubricants or cleaning products containing chlorine, such as household bleach, as these can damage the system and void the limited warranty.
The Flushmate 503 system is backed by a limited warranty, which covers defects in materials and workmanship under normal use. The warranty does not cover damage caused by misuse, improper installation, or the use of non-approved parts or cleaning products.
For additional support, users can contact Flushmate at 800-533-3460 or visit their official website for more detailed instructions and technical support.
Conclusion
The Flushmate 503 Series Pressure-Assist Toilet System is a durable and efficient solution for users seeking a reliable, water-conserving toilet system. The installation process, while requiring some technical knowledge, is manageable for individuals with basic plumbing skills. By following the official manual and taking the necessary safety precautions, users can ensure a successful installation and optimal performance from their new system.
The system’s design emphasizes water efficiency, with a 1.6 gpf rating, and its pressure-assist mechanism ensures a strong and effective flush. Proper maintenance, including winterizing procedures and the use of approved cleaning products, is essential for long-term reliability.
For users who may encounter issues during or after installation, the manual provides detailed troubleshooting steps and contact information for further assistance. By adhering to the manufacturer’s guidelines and recommendations, users can maximize the benefits of the Flushmate 503 system and enjoy a high-performance, water-efficient toilet for years to come.