Monogram 15900-013 User manual

Monogram Systems
1500 Glenn Curtiss, Carson, CA 90746-4012
TOILET ASSEMBLY
Part Number
15900-013
15900-017
15900-020
COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
DISTRIBUTION STATEMENT
This document contains proprietary information of Monogram Systems, and it is issued in strict confidence. Except
for rights expressly granted by contract, this document may not, in whole or in part, be duplicated, reproduced,
disclosed, or used for design or manufacturing purposes without written authorization from Monogram Systems.
38-31-09
T-1
Feb 28/95
Revision 2: Feb 23/04

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900 Series
38-31-09
Page HLT-1
Feb 23/04
TO: Holders of Toilet Assembly (PN 15900-013/-017/-020) Operation and Component
Maintenance Manual, No. 38-31-09 dated Feb 23/04
REVISION NO. 2 DATED Feb 23/04
HIGHLIGHTS
Pages which have been revised or added are outlined below together with the highlights of this
revision. This is a COMPLETE reissue. Please remove and discard affected pages and initial and
date the RECORD OF REVISIONS page.
Chapter-Section-Unit/Page No. Description of Change Effectivity
38-31-09 All models.
Title Page Revised to incorporate new
configuration PN 15900-020.
Record of Revisions Page Add revision 2 and the issued date.
List of Effective Pages Revised to reflect this revision.
Page INTRO-1 Revised.
Pages: 302, 303, 305, 306 Revised text pages to reflect this
revision
Pages: 501, 503 Revised text and Figure 501 to
reflect this revision.
Pages: 702, 703, 705, 709,
711, 712 Revised pages to reflect this revision.
Pages: 1007, 1010, 1015,
1016 Revised pages to reflect this revision.
Pages: 1016.1, 1016.2, 1023.1,
1023.2, 1029.1, 1029.2 Added pages to reflect this revision.
Pages: 1019, 1020, 1021,
1022, 1023 Revised pages to incorporate new configuration PN 15900-020.
Page : 1028 Revised IPL Figure 3 to reflect this
revision.
Page: 1029 Revised page to incorporate new
configuration PN 4650-31.
Pages: 1033, 1033,
1034 Revised pages to incorporate new configuration PN 13503-110.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
RECORD OF REVISIONS
38-31-09
Page RR-1
Feb 23/04
REV
NO.
ISSUE
DATED DATE INSERTED BY
1 May 17/02 May 17/02 M.S.
2 Feb 23/04 Feb 23/04
M.S.
REV
NO.
ISSUE
DATED DATE INSERTED
BY

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
RECORD OF TEMPORARY REVISIONS
38-31-09
Page RTR-1
May 17/02
TEMPORARY
REV. NO. PAGE NUMBER ISSUE DATED BY DATE INSERTED BY

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
SERVICE BULLETIN LIST
38-31-09
Page SBL-1
May 17/02
Service Bulletin
Number Revision Number Date Bulletin Incorporated into Manual

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
LIST OF EFFECTIVE PAGES
38-31-09
Page LEP-1
Feb 23/04
SUBJECT PAGE DATE
Title Page T-1 Feb 23/04
Record of RR-1 Feb 23/04
Revisions
Record of RTR-1 May 17/02
Temporary
Revisions
Service SBL-1 May 17/02
Bulletin List
List of LEP-1 Feb 23/04
Effective LEP-2 Feb 23/04
Pages
Table of TC-1 May 17/02
Contents
Introduction INTRO-1 Feb 23/04
Description 1 May 17/02
and 2 May 17/02
Operation 3 May 17/02
4 May 17/02
Testing and 101 May 17/02
Trouble- 102 May 17/02
shooting 103 May 17/02
104 May 17/02
105 May 17/02
106 Blank
Disassembly 301 May 17/02
302 Feb 23/04
303 Feb 23/04
304 Feb 23/04
305 Feb 23/04
306 Feb 23/04
SUBJECT PAGE DATE
Cleaning 401 May 17/02
402 May 17/02
403 May 17/02
404 Blank
Check 501 Feb 23/04
502 May 17/02
503 Feb 23/04
504 May 17/02
Repair 601 May 17/02
602 May 17/02
603 May 17/02
604 Blank
Assembly 701 May 17/02
702 Feb 23/04
703 Feb 23/04
704 May 17/02
705 Feb 23/04
706 Feb 23/04
707 Feb 23/04
708 May 17/02
709 Feb 23/04
710 May 17/02
711 Feb 23/04
712 Feb 23/04
Fits and 801 May 17/02
Clearances 802 Blank
Special Tools, 901 May 17/02
Fixtures and 902 Blank
Equipment

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
LIST OF EFFECTIVE PAGES
38-31-09
Page LEP-2
Feb 23/04
SUBJECT PAGE DATE
Illustrated 1001 May 17/02
Parts List 1002 May 17/02
1003 May 17/02
1004 May 17/02
1005 May 17/02
1006 Feb 23/04
1007 Feb 23/04
1008 May 17/02
1009 May 17/02
1010 Feb 23/04
1011 Feb 23/04
1012 Feb 23/04
1013 Feb 23/04
1014 Feb 23/04
1015 Feb 23/04
1016 Feb 23/04
1016.1 Feb 23/04
1016.2 Blank
1017 May 17/02
1018 May 17/02
1019 Feb 23/04
1020 Feb 23/04
1021 Feb 23/04
1022 Feb 23/04
1023 Feb 23/04
1023.1 Feb 23/04
1023.2 Blank
1024 May 17/02
1025 Feb 23/04
1026 May 17/02
1023 May 17/02
1028 Feb 23/04
1029 Feb 23/04
1029.1 Feb 23/04
1029.2 Blank
1030 May 17/02
1031 May 17/02
1032 May 17/02
1033 Feb 23/04
1034 Feb 23/04

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page TC-1
May 17/02
TABLE OF CONTENTS
SUBJECT PAGE
Introduction INTRO-1
Description and Operation 1
Testing and Troubleshooting 101
Disassembly 301
Cleaning 401
Check 501
Repair 601
Assembly (Including Storage) 701
Fits and Clearances 801
Special Tools, Fixtures and Equipment 901
Illustrated Parts List 1001

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page INTRO-1
Feb 23/04
INTRODUCTION
1. General
This document is issued to provide instructions for maintaining, troubleshooting,
testing and repairing Toilet Assembly, PN 15900-013/-017/-020 manufactured by
Monogram Systems.
2. Product Support Services
Contact Monogram Systems for repair services, technical documents, replacement
parts, and other support services.
Monogram Systems
1500 Glenn Curtiss
Carson, CA 90746-4012, USA
Telephone: [phone]
Fax: [phone]
3. Layout of Manual
The information in this manual is divided into sections in accordance with Air
Transportation Association, Specification 100 to enable maintenance personnel to
troubleshoot, test, disassemble, clean, check, repair and assemble the toilet assembly
and major components. An illustrated parts list is provided to locate, identify and
requisition parts.
4. Revision Service
To insure that coverage contained in this handbook will reflect changes in maintenance
concepts and procedures, revised information is provided to the customer through a
letter of transmittal advising pages to be removed and added by the revision. The letter
includes a highlights page that identifies the reason of each change and indicates the
effectivity of the change and the service bulletin involved.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 1
May 17/02
DESCRIPTION AND OPERATION
1. General
A. The flushing toilet assembly covered in this manual is a separable assembly of the
toilet installation and is capable of receiving, temporarily storing and during ground
servicing, disposing of waste. Refer to Table 1, Leading Particulars for general
specifications of the toilet assembly.
2. Description
A. The toilet assembly (ref. Figure 1) basically consists of the toilet bowl (1), timer (2),
tank and top assembly (3), motor-pump-filter unit (4), drain valve assembly (5),
solenoid valve assembly (6), liquid level transmitter (7), tie down bracket (8) and hold
down rod (9).
B. The toilet bowl assembly, made of polished stainless steel, is mounted on top of the
tank and top assembly. The timer assembly, a solid-state electronic device used to
control sequence and timing of flushing operation, is also located on the top of the
tank. The tank and top assembly, a Kevlar tank with molded-in structure
reinforcement and top is the reservoir for flushing fluid and waste. The motor-pump-
filter assembly (MPFA) consists of a DC Motor Assembly, static TEF coated
perforated filter, pump impeller and rotating spray nozzle housing. The MPFA is
mounted on the tank with filter submerged in the flushing fluid. The springloaded,
cable actuated drain valve assembly seals the toilet to prevent leakage of stored fluid
and waste and to permit draining and cleaning of the toilet during ground servicing.
The solenoid valve assembly controls the admission of cleansing and charging fluid.
The liquid level transmitter is a solid state electronic device capable of sensing two
discrete points of fill on the toilet tank and transmitting an electronic signal for
precharge level or full-tank level. The level sensors are located on an inside wall of
the tank and the transmitter is mounted on the top of the tank.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 2
May 17/02
1. Bowl Assembly
2. Timer
3. Tank and Top Assembly
4. Motor-Pump-Filter Assembly
5. Drain Valve Assembly
6. Solenoid Valve Assembly
7. Liquid Level Transmitter
8. Tie Down Bracket
9. Holddown Rod
Typical Toilet Assembly
Figure 1

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 3
May 17/02
3. Operation
A. The operation of the toilet begins with the initiation of the flush cycle. The electric
motor of the motor-pump-filter unit assembly is energized for approximately 10
seconds. Throughout the flush cycle, flushing fluid is drawn through the filter by the
pump and discharged into the toilet bowl in a swirling action to wash waste into the
tank assembly.
B. Toilet Assemblies must be serviced after each scheduled flight by emptying, flushing,
and recharging the tanks with fluid containing a dye-deodorant-disinfectant-chemical-
water solution. Draining, cleaning and filling of the toilet assemblies is controlled
from the aircraft toilet ground servicing panel. During toilet tank draining and
cleaning, the tank drain valve is opened. The drain valve is a plunger type valve that
is spring loaded to the closed position. A pull force of approximately 35 pounds
(15,91 Kg) is required to open the valve. During tank cleaning and filling, fresh
water is pumped into the toilet tank from an aircraft lavatory servicing vehicle. The
water enters the toilet tank through an inlet fitting of the solenoid valve assembly,
before going into the rotating spray nozzle via hose connection to the pump inlet.
The rotating spray nozzle is part of the motor-pump-filter assembly. The pressurized
fluid is jettisoned through spray nozzle openings and cleanses the inside of the filter
basket and tank side walls at same time precharge fluid is added. After the cleaning
operation the Liquid Level Transmitter will indicate when the fluid reaches the proper
pre-charge level.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 4
May 17/02
Table 1
Leading Particulars
Use Toilet Facilities
Electrical Power Rating +28 VDC, 5 AMPS Nom.
Fluid Pump Capacity (Nominal) 10.0 +1 GPM (37,85 +3,79 LPM)
Flushing Cycle (Nominal) 10 +2 Seconds
Tank Capacity 5.3 Gal (20,06 Liters)
Usable Capacity 2.8 Gal (10,60 Liters)
Priming Precharge 1.0 Gal (3,79 Liters)

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 101
May 17/02
TESTING AND TROUBLESHOOTING
1. Testing
A. Place complete toilet assembly over sink or drain opening. Arrange with toilet drain
valve opening above sink or drain.
B. Connect 28 VDC Power to the toilet. See the wiring diagram (Figure 101) for
connection.
C. Connect a variable pressure water source to the water inlet fitting.
D. Rinse Test
(1) Introduce the water source at 60 psi(g) to the tank. Check and ensure that
solenoid valve is open.
(2) Observe pump spray nozzle for free rotation and adequate rinsing of the toilet
tank.
(3) Remove the water source and disconnect the power source.
(4) Check and ensure that the solenoid valve is closed. Check for leaks around the
inlet fitting, antisiphon valve and pump exterior.
E. Motor Pump and Timer Test
(1) Connect the pump and timer to a regulated power supply that conforms to
specified voltage and current requirements.
(2) Depress pushbutton switch and note toilet function. Cycle duration shall be 10
+2 seconds. The swirl pattern should be consistent and vigorous, washing the
complete inner surface of the bowl.
(3) Repeat flush cycle 3 to 4 times.
(4) Measure current surge and running current drain (5 amps nominal).
(5) Inspect for leaks around inlet tube and antisiphon valve.
(6) Drain toilet.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 102
May 17/02
F. Bowl Flushing Test
(1) Fill the toilet tank to the specified precharge level (see Leading Particulars).
(2) Upon flushing the toilet it should be observed that the bowl is completely wetted
and water action is vigorous without excessive splashing.
(3) Repeat flushing operation four times to confirm adequate bowl coverage and
water action.
(4) Drain toilet.
G. Liquid Level Sensor Test
(1) Connect the liquid level sensor to the appropriate test harness.
(2) Fill the toilet tank to the precharge level.
(3) Ensure that the precharge indicator light is on.
(4) Continue filling the toilet tank to the full level as indicated in the drawing.
(5) Ensure that the full indicator light is on, and the solenoid valve is shut off.
H. Leak Test
(1) Cap the tank vent. Fill the toilet through the bowl aperture until the water level
is approximately one inch below the bowl flush ring.
(2) Remove any air trapped within the tank.
(3) Allow the toilet to remain in this condition for one hour after which there shall
be no evidence of leakage from any of the toilet components, including the toilet
tank, tank top, gaskets and fitting.
I. Disconnect water supply.
J. Disconnect power supply.
K. Drain all water from tank and remove all water from components.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 103
May 17/02
2. Troubleshooting
A. The troubleshooting information given in Table 101 deals with problems encountered
during testing of the toilet assembly. Before performing troubleshooting remedies,
check all wiring and electrical connections, pressurized hose connections and drain
piping for general condition. Repair/replace as required.
Table 101
Troubleshooting
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Toilet tank does not rinse
during servicing. Solenoid valve assembly held closed. Replace LLT. Replace solenoid valve
assembly.
Check power to solenoid
valve assembly and aircraft
wiring.
Spray nozzle will not rotate,
motor and pump operative. Spray nozzle clogged or not installed properly. Clean and install parts properly (refer to
DISASSEMBLY and
ASSEMBLY).
Toilet tank floods during
servicing. Solenoid valve assembly stuck open. Replace LLT. Replace solenoid valve
assembly.
Check aircraft wiring of
LLT and solenoid valve
assembly.
Solenoid valve assembly
leaking. Faulty or leaky solenoid valve assembly. Replace solenoid valve assembly.
Toilet will not flush (motor-
pump-filter does not
operate).
Motor-pump-filter inoperative.
Faulty timer.
Faulty LLT.
Faulty solenoid valve assembly.
Faulty wiring.
Replace motor-pump-filter
assembly.
Replace timer.
Replace LLT.
Replace solenoid valve
assembly.
Check aircraft wiring.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 104
May 17/02
Table 101
Troubleshooting (cont)
TROUBLE PROBABLE CAUSE CORRECTIVE ACTION
Toilet will not flush (motor-
pump-filter running). Foreign object obstruction of flushing fluid passages. Inspect discharge tube.
Pump inoperative. Sheared pump drive shaft. Replace drive shaft
coupling.
Motor-Pump-Filter noisy. Improperly assembled or
damaged motor-pump-filter assy. Replace motor-pump-filter unit assy.
Motor runs continuously or
excessively long. Malfunction in timer assembly. Replace timer.
Leakage from tank drain. Drain valve not sealed. Inspect drain outlet valve
seat area of tank for cracks,
chips and scratches.
Replace drain valve assy.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 105/106
May 17/02
WIRING DIAGRAM
Figure 101

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 301
May 17/02
DISASSEMBLY
1. General
NOTE: See TESTING AND TROUBLESHOOTING, to establish the condition of
component or most probable cause of its malfunction. This is to determine the
extent of disassembly required without completely tearing down and
rebuilding the components.
A. Disassembly instructions given herein presume that complete overhaul of the toilet
assembly is to be accomplished. Disassembly instructions cover disassembly only as
far as practicable; however, these instructions enable disassembly to provide adequate
access for inspection and cleaning. In some instances, partial equipment overhaul, or
overhaul of individual sub-assemblies only, may be required. In this event,
disassembly shall be conducted only to the extent necessary to accomplish removal
and installation of affected assemblies.
B. Prior to initiating disassembly operations, personnel shall carefully read all
instructions and study illustrations applicable to the equipment undergoing overhaul.
The toilet assembly shall be in a clean condition, free of contamination and residue,
before disassembly is begun. Refer to CLEANING if additional cleaning is required.
C. The disassembly procedures presented here provide instruction and sequence for the
removal of major components and most detail parts.
D. Each of the following paragraphs describes disassembly of the toilet assembly or a
component assembly. The part number of each assembly, to which the procedure
applies along with the corresponding exploded illustration figure, is noted in the
paragraph heading.

Monogram Systems
COMPONENT MAINTENANCE MANUAL
BASIC PN 15900
38-31-09
Page 302
Feb 23/04
2. Procedure
A. Toilet Assembly, PN 15900-013/-017/-020 (refer to IPL Figure 1)
(1) If damaged or illegible, remove decal (5).
NOTE:Nut (25), washer (30) and eye bolt (35) are attached to the aircraft structure
and should not be removed.
(2) The toilet assembly is held in position in the aircraft with rod (20). Remove toilet
assembly from aircraft as follows: loosen nuts (10), washers (15 or –15A) and
swing rods (20) away from the tank and top assembly (535, -535A or –535B).
(3) Remove flush hose (40) by removing clamps (45).
(4) Disconnect grounding strap (50).
(5) Remove bowl assembly (55) by removing nuts (60) and washers (65 or –65A).
(6) Remove restrictor (70).
(7) Inspect bowl gasket (75), remove and discard if necessary.
(8) Remove fill line hose (100) by removing clamps (105).
(9) Remove motor-pump-filter assembly (110 or –110A) by removing nuts (115)
and washers (120 or –120A).
(10) Remove solenoid valve assembly (125 or –125A) by removing nuts (130) and
washers (135 or –135A).
NOTE:If damaged or defective, contact pins (140), connectors (145 and 150), hose
adaptors (155) and mounting brackets (160) may be removed from solenoid
valve (165).
(11) Remove vent fitting (185) and gasket (200) by removing nuts (190) and washers
(195 or –195A).
(12) Remove pulley (205) by removing cotter pin (215), clevis pin (210) and washer
(220 or –220A).
(13) Remove pulley bracket (225) by removing nuts (230) and washers (235 or –
235A).
(14) Remove pulleys (255) by removing cotter pins (245), clevis pins (240 and 260),
washers (250 or –250A) and roll pin (275).