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Thetford Cassette C2 User Manual

Thetford Cassette C2
44 pages
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TOILET REPAIR GUIDE
CONTENTS
Porta Potti
Bellows, Inlet Tube & Flush Tube Replacement
Page 1-2
Float Arm Replacement
Page 3
Vent seal, Lipseal & Vent Button Replacement
Page 4-5
Bellows to Piston Pump Exchange Page 6
Cassette C2/C4
Pump Replacement
Page 7-8
Vent Seal and Lip Seal Replacement pre 2000
Page 9-10
Bellows, Inlet Tube & Flush tube for Early C4 Page 11-12
C2 Vent Button Replacement
Page 13
Flush Mechanism C2
Page 14-15
Drain Tube
Page 16-17
Automatic Vent
Page 18
Float Arm Replacement
Page 19
Level Indicator
Page 20
Flush tube
Page 21
Blade Mechanism
Page 22-23
C2
Lip Seal After 2000
Page 24
Cassette C200
Blade Opener
Page 25-26
Level Indicator
Page 27-29
Manual Pump
Page 30-31
Float Arm
Page 32
Seat Hinge Pin Page 33
Lip Seal
Page34
Blade Handle
Page 35-36
Cassette C400
Fuse Replacement
Page 37
Reed Switch
Page 38
Control Panel Removal
Page 39-40
Pump Replacement
Page 41-43
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Thetford Cassette C2 Specifications

General IconGeneral
Waste tank capacity17 liters
Level indicator waste tankYes
Toilet typeCassette toilet
Seat rotationNo
MaterialPlastic
Battery OperatedNo
Flush water tank capacity15 liters
Flush systemManual
Compatible ChemicalsThetford Aqua Kem

Summary

Porta Potti Inlet Tube and Bellows Replacement

Disassemble water tank, seat, and cover

Take apart the water tank, seat, and cover for access.

Replace bellows and inlet tube

Procedure for removing the old bellows and fitting the new one.

Porta Potti Flush Tube Replacement

Install new flush tube and nozzle

Shape and insert the new flush tube, guide nozzle into bowl.

Porta Potti Float Arm Replacement

Prepare for float arm removal

Position float arm and access waste tank for retainer removal.

Replace float retainer and arm

Remove old retainer, install new one, and fit new float arm.

Porta Potti Ventseal Replacement

Remove and install ventseal

Push out old ventseal, fit new one and close blade.

Porta Potti Lipseal Replacement

Remove and install lipseal

Pull out old lipseal, fit new one into groove and close blade.

Porta Potti Vent Button Replacement

Remove vent button assembly

Press button to loosen retainer, then pull loose.

Install new vent button assembly

Fit new spring and button, then push in seal retainer.

Porta Potti Bellows to Piston Pump Exchange

Disassemble toilet and remove bellows

Take apart water tank, remove bellows and inlet tube.

Install piston pump

Connect piston pump to flush tube and place into water tank.

Cassette C2 Pump Replacement

Access pump location

Remove tissue well and holder to reach the pump.

Remove and disconnect pump

Unscrew pump retainer, remove pump, disconnect flush tube.

Prepare and connect pump wires

Cut cable, strip wires, and connect using shrinktube.

Cassette C2 Pump Replacement (Wiring)

Melt shrink tube for wire protection

Use hot-air gun to melt shrink tube over wires.

Reassemble pump and connect flush tube

Connect flush tube, screw pump back, replace parts.

Cassette C2 Ventseal Replacement (Early Model)

Remove old ventseal

Depress and pull the ventseal out of the seal.

Install new ventseal

Fit new ventseal into the hole and press from inside.

Cassette C2/C3/C4 Lip Seal Replacement (Pre-2000)

Remove seal cover

Unscrew the 8 screws and take the seal cover off.

Replace seal cover

Ensure cut-outs align, then replace the seal cover.

Cassette C2 Bellow, Inlet Tube, Flush Tube Replacement (Early)

Remove cylinder, cap, and nozzle

Take out cylinder, bellows cap, and nozzle.

Replace inlet tube or flush tube

Procedure to replace inlet tube or flush tube.

Replace bellows

Remove old bellows and fit new bellows into housing.

Reassemble nozzle and flush tube

Fit nozzle and assemble inlet tube and flush tube.

Cassette Flush Mechanism Replacement

Remove flush cap and mechanism

Lift flush cap and pull out flush mechanism by hand.

Replace nozzle and reassemble mechanism

Fit new nozzle and reassemble mechanism with lug alignment.

Cassette Vent Plug and Button Replacement

Remove vent plug

Turn and lift the vent plug out of the waste tank.

Replace vent button

Fit new spring and button, then secure with retainer.

Cassette C2/C3 Mechanism Replacement

Remove waste tank and flush knob

Pull waste tank out and remove flush knob and insert.

Remove mechanism housing

Take out the mechanism housing secured by screws.

Cassette C2/C3 Mechanism Replacement (Reassembly)

Connect mechanism parts

Remove screws, pull connector, and attach to new mechanism.

Reassemble mechanism and flush knob

Screw mechanism back, then attach flush knob.

Cassette C2/C4 Drain Tube Replacement (LH)

Remove waste tank and bracket

Pull out waste tank and unscrew the bracket.

Remove drain tube from tank

Remove drain tube from four locations.

Install new drain tube and plug

Fit new drain tube, clamp collar, and blind plug.

Cassette C2/C4 Drain Tube Replacement (LH - Pump/Linkage)

Prepare pump and linkage access

Take out tissue well and holder to access pump.

Replace pump and linkage

Unscrew pump, place linkage, and screw together.

Connect flush tube and position pump

Connect flush tube and position pump on left side.

Cassette C2/C3/C4/C200 Automatic Vent Replacement

Remove automatic vent

Turn the automatic vent to the left and take it out.

Install new automatic vent

Place new vent and turn to the right to lock it.

Cassette C2/C3/C4 Float Arm Replacement

Position float arm and access tank

View float arm position and access waste tank.

Replace float retainer and arm

Remove retainer, install new one, and fit new float arm.

Cassette Level Indicator Replacement

Remove old level indicator

Unscrew the 7 screws underneath the level indicator.

Install new level indicator

Screw the 7 screws back into the toilet.

Cassette Flush Tube Replacement

Remove pump and flush tube

Access pump, unscrew retainer, and pull nozzle down.

Install new flush tube

Fit new nozzle, press into hole, and connect flush tube.

Cassette C2/C3/C4/C200 Blade Replacement

Remove sliding and seal covers

Remove sliding cover and unscrew seal cover.

Remove and replace blade

Gently pull blade out of blade arm.

Cassette C2/C3/C4/C200 Blade Replacement (Cont.)

Install new blade and test

Press new blade, open/close blade to test mechanism.

Replace lip seal and covers

Place lip seal, screw back covers, then sliding cover.

Cassette C2/C3/C4 Lip Seal Replacement (Post-2000)

Remove sliding and seal covers

Remove sliding cover and unscrew seal cover.

Replace lip seal and covers

Place lip seal, screw back seal cover, and replace sliding cover.

Cassette C200 Blade Opener Replacement

Access blade opener

Note tank is sealed; remove retainer to access opener.

Remove blade opener

Press sides slightly to remove the blade opener.

Cassette C200 Blade Opener Replacement (Cont.)

Install blade arm driver

Position blade arm driver on track support.

Replace blade opener and retainer

Fit blade opener and retainer into position.

Cassette C200 CW Level Indicator Replacement

Remove bezel and screws

Unscrew the two bezel screws and lift the bezel.

Remove indicator screws

Unscrew the four screws holding the level indicator.

Cassette C200 CW Level Indicator Replacement (Wiring)

Remove seal and cut cables

Remove seal, move backwards, and cut the two cables.

Connect new LED and shrink tubes

Connect cables to new LED using shrink tubes.

Cassette C200 CW Level Indicator Replacement (Cont.)

Melt shrink tubes and move seal

Melt shrink tubes with drier, move seal forward to LED.

Replace seal, cable, and screw back

Replace seal, cable, and screw the four screws back.

Cassette C200 CW Manual Pump Replacement

Remove bezel and pump retainer

Remove bezel, push up, and unscrew the pump retainer.

Remove pump and tube

Take out pump and remove tube from vacuum breaker.

Cassette C200 CW Manual Pump Replacement (Cont.)

Place new pump tube

Place tube from new pump onto vacuum breaker.

Mount new pump and apply sealant

Mount new pump in tank, apply sealant before bezel replacement.

Cassette C200 Float Arm HT Replacement

Position float arm and remove retainer

View float arm position and remove float arm retainer.

Install new float arm

Place new float arm into tank and press until it clicks.

Cassette C200 Hinge Pin Replacement

Remove seat and hinge pins

Remove the seat and then the hinge pins with screwdriver.

Replace hinge pins and seat

Fit new hinge pins and replace the seat on the toilet.

Cassette C200 Lip Seal Replacement

Remove sliding and seal covers

Remove sliding cover and unscrew seal cover.

Replace lip seal and covers

Place lip seal, screw back covers, and replace sliding cover.

Cassette C200 Valve Blade Handle Replacement

Remove waste tank and bracket

Pull waste tank out and unscrew saddle bracket.

Remove seal handle and link

Unscrew seal handle and remove the link.

Cassette C200 Valve Blade Handle Replacement (Cont.)

Place new handle and seal

Place new handle and seal on ring inside toilet.

Assemble screw and re-assemble bracket

Assemble screw into bushing and re-assemble bracket.

Cassette C400 Blade Fuse Replacement

Remove waste tank and reed switch

Pull waste tank out and remove reed switch HT.

Replace blade fuse and reed switch

Place new blade fuse and replace reed switch HT.

Cassette C400 Reed Switch HT Replacement

Remove waste tank and disconnect switch

Pull waste tank out and disconnect reed switch HT.

Connect new switch and place back

Connect new reed switch HT and place back into toilet.

Cassette C402 C Control Panel Replacement

Remove handle and control panel

Remove handle, then remove control panel.

Disconnect and connect panel connectors

Disconnect and connect the control panel connectors.

Cassette C402 C Control Panel Replacement (Cont.)

Replace new control panel

Place the new control panel into position.

Replace handle

Fit the handle back onto the panel.

Cassette C402 C X Pump Replacement

Remove handle, panel, and well

Remove handle, control panel, and control well.

Remove seal and take pump out

Remove seal from control well, take pump out of watertank.

Cassette C402 C X Pump Replacement (Wiring)

Prepare pump wires

Cut cable, strip wires, and place shrink tube.

Connect wires and shrink tube

Connect wires and place shrink tube on connectors.

Cassette C402 C X Pump Replacement (Cont.)

Melt shrink tube and replace pump

Melt shrink tube and replace pump and seal in control well.

Replace control well and panel

Replace control well, control panel, and handle.

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