The Flushmate 503 Series Pressure-Assist Toilet System is a high-performance flushing solution designed to enhance water efficiency and flushing power in modern residential and commercial toilets. This article provides a detailed overview of the installation process, maintenance procedures, and operational requirements for the system, based exclusively on the technical documentation provided by Flushmate.
Introduction
The Flushmate 503 Series is a pressure-assist system that uses a combination of water and air to create a powerful and efficient flush. The system is engineered to operate with a minimum water pressure of 20 psi (137.9 kPa) and a maximum of 80 psi (551.6 kPa), with a minimum water flow rate of 1 gallon (3.79 liters) in 30 seconds. These specifications are critical to ensuring the system performs as intended.
Installation of the Flushmate 503 Series requires careful attention to detail, as the system must be properly aligned and secured within the toilet tank. The documentation emphasizes the importance of following all safety precautions, including ensuring the system is depressurized before beginning work and using appropriate tools to avoid injury or damage.
This article is structured to guide the reader through the key steps of installation, troubleshooting common issues, and performing seasonal maintenance such as winterization. It also includes a detailed breakdown of the system components and their functions, as well as a summary of the limited warranty and customer support options.
System Overview and Components
The Flushmate 503 Series Pressure-Assist System is composed of several key components that work together to provide efficient and powerful flushing performance. Understanding these components is essential to both the installation and maintenance of the system.
Flush Valve Cartridge: This component controls the flow of water and air during the flush cycle. It is mounted on the vessel and must be properly adjusted to ensure the system functions correctly.
Actuator: The actuator is the handle or lever used to initiate the flush. It is connected to the flush valve cartridge and must be adjusted to the correct height to ensure proper operation.
Flushmate Vessel: The vessel is the central component of the pressure-assist system. It stores water and air under pressure and releases them during the flush cycle.
Discharge Extension: This part connects the vessel to the toilet tank and allows water and air to be expelled during the flush.
Lower Supply Group + Hose: The lower supply group includes the supply shank and locknut, which connect the system to the water supply line. The hose is responsible for delivering water to the vessel.
Upper Supply Group: This includes the inlet screen, pressure regulator, back check valve, and pressure relief valve. These components regulate the flow of water into the vessel and maintain proper pressure levels.
Air Inducer Cap and Duckbill: These parts help to introduce air into the system, which is essential for the pressure-assist function.
Gaskets and Locknuts: These seals and fasteners are used throughout the system to ensure airtight and watertight connections. They must be replaced during installation to maintain system integrity.
Tool Kit (Optional): The tool kit includes a 4-in-1 tool for tightening and loosening screws and nuts during installation. It is recommended for users who are not familiar with the specific tools required for the system.
Installation Process
The installation of the Flushmate 503 Series Pressure-Assist System requires a step-by-step approach to ensure proper alignment, sealing, and functionality. Below is a detailed breakdown of the installation process, based on the instructions provided in the documentation.
Preparation and Safety Precautions
Before beginning the installation, it is important to review the entire manual and gather all necessary tools and materials. The documentation emphasizes the importance of following safety precautions, including:
- Turn off the water supply to the toilet to prevent accidental flooding or injury.
- Release pressure from the Flushmate vessel by flushing the toilet to ensure the system is depressurized.
- Avoid contact with exposed tank bolts, which have sharp threads that may cause injury.
- Use a towel to wipe up excess water to prevent slip-and-fall hazards in the work area.
- Lift the toilet tank carefully, as it may weigh up to 45 lbs (20.4 kg). If assistance is needed, contact Flushmate at 1.800.533.3460.
Removing the Old System
If the Flushmate 503 Series is being installed as a replacement, the old system must be removed first. The process includes the following steps:
- Turn off the water supply and flush the toilet to release pressure from the vessel.
- Disconnect the water supply line and place a bucket underneath the supply shank to catch any remaining water.
- Remove the discharge locknut using the 4-in-1 tool. Depending on the tank bolt configuration, the toilet tank may need to be repositioned for better access.
- Slide the old Flushmate system out of the tank and dispose of it according to local waste handling procedures.
- Remove any debris from inside the tank to ensure a clean installation area.
Installing the New Flushmate System
Once the old system has been removed, the new Flushmate 503 Series can be installed. The process is outlined as follows:
- Place the new tank-to-tank gasket on the discharge extension with the flat side facing the vessel.
- Align the Flushmate vessel with the toilet tank as shown in the manual.
- Release the lower supply group from the vessel’s mounting post by gently wiggling it and pulling it free.
- Guide the supply shank through the small opening at the bottom of the tank and thread on the supply shank locknut by hand.
- Insert the new Flushmate system into the tank, ensuring the discharge extension passes through the center opening.
- Hold the vessel in place while hand-tightening the discharge extension locknut. Be careful not to cross-thread the locknut.
- Tighten the tank bolts using the 4-in-1 tool. Some toilets may have rubber spacers that should be temporarily removed for tightening.
Adjusting the Actuator and Flush Valve Cartridge
After the system is installed, the actuator and flush valve cartridge must be adjusted to ensure proper operation. The process includes the following steps:
- Hold the actuator in place and tighten the set screw using the 4-in-1 tool.
- Loosen the set screw by turning it counter-clockwise approximately 4 turns using the 3-in-1 wrench.
- Unscrew and remove the actuator and set it aside for reinstallation.
- Turn the flush valve cartridge counter-clockwise using the 3-in-1 wrench until only one black thread of the vessel is visible.
- Turn the flush valve cartridge clockwise ¼ turn to allow water to stop running. Wait 30 seconds between each turn and test the system by flushing the toilet twice, waiting 1 minute between flushes.
If the water continues to run after two attempts, the process should be repeated. If it still does not resolve the issue, contact Flushmate at 1.800.533.3460 for further assistance.
Troubleshooting and Maintenance
The Flushmate 503 Series is designed for reliable performance, but like any mechanical system, it may require troubleshooting or maintenance over time. Below are some common issues and solutions based on the documentation.
Water Running Continuously After Flush
If the water continues to run after a flush, it may indicate an issue with the flush valve cartridge or actuator. The following steps can be taken to resolve the issue:
- Loosen the set screw on the actuator and turn the flush valve cartridge counter-clockwise in ¼ turn increments. Wait 30 seconds between each turn and test the system after each adjustment.
- Listen for the water to stop running. If it does, the issue has likely been resolved.
- If the water continues to run, repeat the adjustment process. If it still does not resolve the issue, contact Flushmate for further assistance.
Winterization
In colder climates, it is important to winterize the Flushmate system to prevent damage from freezing temperatures. The following steps should be followed:
- Turn off the water supply to the toilet.
- Release pressure by flushing the toilet to empty the vessel.
- Drain the water from the system by disconnecting the supply line and placing a bucket underneath the shank.
- Push the actuator down and hold it for 5 seconds to allow residual water to drain.
- Pull the actuator up and hold it for 5 seconds to allow air to enter the vessel.
- Sponge out any remaining water from the tank.
- Follow any additional winterization instructions provided by the toilet manufacturer.
It is important to note that no antifreeze or chemical agents should be used in the toilet tank or Flushmate system, as this will damage the system and void the warranty.
Limited Warranty and Customer Support
The Flushmate 503 Series comes with a limited warranty that covers defects in materials and workmanship under normal use and service. The warranty does not cover damage caused by misuse, improper installation, or the use of non-recommended products such as petroleum-based lubricants or chlorine-based cleaning agents.
Customers are encouraged to contact Flushmate at 1.800.533.3460 for assistance with installation, troubleshooting, or warranty claims. The company also provides a comprehensive website with additional resources, including installation guides, product specifications, and customer support.
Conclusion
The Flushmate 503 Series Pressure-Assist Toilet System is a reliable and efficient solution for modern toilets that require a powerful and water-efficient flush. Proper installation, adjustment, and maintenance are essential to ensuring the system performs as intended. By following the detailed instructions provided in the documentation, users can safely and effectively install the system and troubleshoot any issues that may arise.
The system is designed for ease of use, but it is important to take all necessary precautions, including depressurizing the system before installation and using the correct tools to avoid injury. Additionally, winterization is a critical step in colder climates to prevent damage from freezing temperatures.
For users who are unsure about any aspect of the installation or maintenance process, it is recommended to consult with a qualified plumber or contact Flushmate directly for assistance. With proper care and attention, the Flushmate 503 Series can provide years of reliable performance and efficient flushing.