Thetford C2 Assembly instructions

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

1. 07016-07024 Inlet tube / 07862 Bellow
A.
Disassemble water tank from waste tank and, take
seat & cover off.
B. Cut half off the
bellow with the
knife and, take
the bellow out.
C.
D.
Take the inlet tube off the bellow and, (re)place
it on the new bellow.
Note: Make sure that the flapper inside inlet tube
is pointing downwards when assembled on the
new bellow.
Inlet tube Flapper
E. Connect bellow
to the flush tube
and, press it back
into the water tank.
Flush tube
F. Place seat & cover back onto the water tank.
Note : Turn the
water tank around
when holding the
bellow with the
pincers.
Take the bellow off
the flush tube.
1

Leaflet no. 07032/062001
2. 07031 Flush tube
D. Go inside nozzle
with the long nose
pliers and, push it
into the water tank.
Nozzle
E. Bend the new flush tube into a horseshoe shape and place an
elastic band around it half way down, forcing it to remain in
this position.
For taking out the bellow see point A, B and C on the front page.
F. Once in view the nozzle
may then be gripped with
a long nose pliers and
pulled back into the toilet
bowl through the hole.
G. When pulling the nozzle through the hole,
make sure that the small rib on the nozzle
is pulled inside the toilet bowl.
Due to the horseshoe shape of the flush tube, when refitted, the
nozzle will be guided back up towards the hole at the entrance of
the bowl.
Small rib
Note : Before refitting,
remove the elastic band.
2

21322 Float arm
2. Porta Potti
Note : If the float retainer is still in the waste tank (float arm has fallen off), the new float arm can not be
assembled. Float retainer has to be taken out first. This can be done with a small flat screwdriver.
As the waste tank is welded, this can only be done through the hole in the middle.
Inside view to take the
float retainer out.
Place screwdriver
between rib and float
retainer and lift it up.
A.
Float arm
Float retainer
B.
For placing the new
float arm, open the
blade and go with
your hand in the
waste tank.
Magnet always has to
point to the outside of
the waste tank.
Inside view
waste tank. Press the float retainer
in.
C.
Leaflet no. 21774/052001
Place where float arm
has to be assembled
Position float arm,
view from the outside.
Magnet pointed
to the outside
3

1. 07102 Ventseal / 07069 Ventseal
2. 07101 Lipseal / 07143 Lipseal
1.
2.
Push the ventseal
down, out of the
inside groove.
Pull the ventseal
out through the
hole.
Hold the ventseal
in position with the
flat screwdriver (1),
while closing the blade
slowly (2).
Pull the lipseal
out of the
inside groove.
Push the lipseal
into the inside
groove, and close
the blade.
Note: Top has to
be pushed in first.
Inside groove
Inside groove
A.
B.
C.
A.
B.
C.
4

3. 07524 Vent button / 29314-62 Vent button
Leaflet no. 21283/042001
3.
2.
Go with your hand
in the waste tank
and press the vent
button (3).
While pressing
the vent button,
pull the seal
retainer loose (1).
1 2 3
1. Seal retainer
2. Spring
3. Vent button
Bring new seal
retainer (1) and
spring (2) in
position and click
the vent button (3)
into the seal retainer
1.
1.
3.
A.
B.
C.
5

Disassemble water tank from waste tank and, take
seat & cover off.
Cut half off the
bellow with the
knife and, take
the bellow out.
Note : Turn the
water tank around
when holding the
bellow with the
pincers.
Take the bellow off
the flush tube.
Leaflet no. 35305/092005
25817-79 / 25818-68/79 Piston pump
A. Change over from bellow to piston pump
Flush tube
Note : before placing
the Piston Pump, please
remove the grey sealant
which was used for the
bellow.
Take the piston pump
and connect it to the
flush tube.
Place the piston pump
on its place and press it
back into the water tank
6

16374 Pump
Tissue well
Tissue holder
A.
Take tissue well and
tissue holder out to
get to the location of
the pump.
Tissue well
Disconnect the
flush tube from
the pump.
B.
Unscrew the screw
on the pump retainer
and take complete pump
out of the water tank.
C.
Pump retainer
D.
Tools which are needed :
1. Screwdriver (crosshead)
2. Stanley knife
3. Combination pliers
4.Wire-stripper
5.Connector pliers
6. Hot-air gun
1.
1. 2. 3.
6.
5.
4.
1. Pump
2. Pump retainer
3. Shrinktube
3. 1.
2.
Cut the cable just
above the pump with
the combination pliers.
F.
Cut the white wire
insulation off so that
the blue and brown
wire stay intact and
strip the blue and
brown wire with the
wire-stripper.
G. Place the pump retainer
and shrinktube on the
new pump before
Note : Cassette toilets produced between 1987 and 1989 have
two black connectors on the white cable.
If this is the case, the white cable has to be cut above
the black connector. Both connectors have to be taken
off.
E.
connecting the wires to each other
(blue-blue/brown-brown) with the connector pliers.
C2
7

H.
Leaflet no. 21036/062001
Place the
shrinktube
over the connected wires and
melt the shrinktube with the hot-air gun.
*Melting the shrinktube will prevent that the
connected wires will come in contact with the
water in the water tank.
Note : When melting the shrinktube make
movements from left to right so that the
shrinktube can melt gradually.
CAUTION : Make sure that the shrinktube is melted completely to the white wire insulation as
otherwise a short circuit can occur.
Also keep in mind that the shrinktube should not be touched after melting, because
of burning.
I. Connect flush tube back onto
the pump and screw the pump
back into the water tank.
Place tissue holder and
tissue well back into
the water tank.
J.
8

8x
Seal cover
8x
20339 Ventseal
A. Open the blade,
and depress the
ventseal (1) around
outer edge of seal (1a).
Take the ventseal out
(2).
1. 2.
B. Bring new ventseal
on its place as shown.
Thinner flange has to
be on the float which is
inside the waste tank.
Thinner flange Float
Depress the ventseal
through the hole,
from the outside.
Note: Make sure that
the ventseal is lying in
the middle of the hole,
when looking from the top.
C. Go with your hand
in the waste tank and
press against the
float (ventseal will
be pressed into its place).
Outside view:
float inside waste tank Inside view: press against float
1a.
Early C2
9

13/07/2006 Description: C2 C3 C4
(produced until 15 June
2000) Lip seal
13/07/2006Date:
Tools required:
V2Version:
Description: C2 C3 C4 (produced until 15 June 2000) Lip
seal
Part number: 16175
Look for Service Centers, Point of Sale addresses and other
information on: www.thetford-europe.com
A
Repair instruction
B
Unscrew the 8 screws
on the seal cover and,
take the seal cover off.
Ensure the two cut outs
on the seal face
upwards and line up with
the two centre screws
of the three positioned
on either side of the seal
cover.
Seal cover
8x
Cut outs
C8x
Replace the seat cover.

Pump, Inlet tube, Flush tube & Bellow Replacement
A. Lift the flush cap (1)
up with your finger.
B. Push cylinder (2) down
and turn it to the left to
take it out. After this,
the bellow cap (3) and
housing (4) can be taken
out.
2. 3.
1.
C.
4.
Inside view,
nozzle (5) has
to be taken out.
Can be pulled
down.
5.
D.
6.
7.
Bring nozzle back
into the hole and
press it up (you will
hear a click).Note :
Rib on nozzle has to go
through the hole, to the
inside of the toilet bowl.
Push housing
in by hand
Turn the lug (1)
on the housing,
against the lug (2)
on the actual
Cassette toilet. 1.
2.
Inlet tube (6),
Flush tube (7) or
Bellow (8) can now
be replaced
6.
8.
7.
Note : Inlet tube and Flush tube can easily be replaced by pulling of the part and press the new part on.
For replacing the Bellow see following instructions.
Bellow is fitted
into the housing
with PTI (kind of
kit). Depress bellow
firmly loose (1) and
pull it out (2).
When placing the new
bellow, hold the parts
in position as on the
photo. Lug on the housing
has to be on the right side.
Lug
Press the bellow
into the housing and,
assemble inlet tube and
flush tube.
Cylinder can only
be pressed in one
way (single rib has
to face the backside
of the toilet).
2 x double rib
single rib
E.
Rib
Rib inside
Toilet bowl
11
Early C2

2. 20291-62 Flush mechanism
A. Lift the flush cap (1)
up with your finger.
B. Flush mechanism
can be pulled out
by hand.
Inside view,
nozzle (2) has
to be taken out.
Can be pulled
down.
C.
F. and turn it to the right.
Bring nozzle from new
flush mechanism back
into the hole and press
it up (you will hear
a click). Note : Rib on
nozzle has to go through
the hole, to the inside of
the toilet bowl.
Turn the lug (1)
on the housing,
against the lug (2)
on the actual
Cassette toilet.
D.
1.
2.
Push in
by hand
1.
2.
Leaflet no. 21039/052001
Rib Rib inside
toilet bowl
E.
12

16176-74 Vent plug / 07524-78 Vent button
Leaflet no. 20278/082001
A.
Turn the vent plug away
from the arrow on the
waste tank ( can only be
turned one way) and lift
it up.
Note : some force may
be needed to take the
vent plug out.
C.
*Vent plug can now be replaced. If the vent button has to be replaced, please follow underneath
instructions.
1. Vent plug
2. Vent button
3. Spring
4. Seal retainer
1.
2. 3. 4.
Press the vent button in
and pull the seal retainer
loose.
2.
4.
D. Place new spring and vent button in
the vent plug and push the new seal
retainer in.
Note : Press the vent button in while
assembling the new seal retainer.
E. Place vent plug back into the waste
tank and turn the two arrows back
to each other
When the vent plug is
locked into the waste tank,
the two arrows (one on the
waste tank and one on the
vent plug) has to be pointed
to each other.
B.
13

16379-74 Mechanism Cassette C2/C3
Pull the waste tank out of the
Cassette toilet by lifting up
the yellow clip.
B.
Screwdrivers :
Flat
Crosshead
Materials needed
A.
Place flat screwdriver under the small
plastic insert, which is in the middle of
the flush knob, and take it off.
Unscrew the one screw
inside the flush knob, with
the crosshead screwdriver
Flush knob
Complete flush knob
can now be taken out.
After the flush knob, the mechanism housing has to be
taken out. Note :This can only be done from the outside.
C.
When looking inside the Cassette toilet from the
outside, the mechanism is screwed to the
underside of the water tank.
Mechanism housing which is located inside
the Cassette toilet with four screws (on each
corner).
14

Leaflet no. 20268/032002
D.
Remove the four screws located on the
mechanism, allowing it to drop down.
Note : On Cassette toilets which are
produced between 1987 and 1989,
5 screws should be removed.
Pull the white connector loose from the mechanism,
and press the connector into the new mechanism.
4 x
4 x
E.
Screw the mechanism
back on its place. Place flush knob back (in the same position as on the photo, see
print on the knob) and, screw it back into the toilet with the
crosshead screwdriver.
15

21370 Drain tube LH
A.
Pull the waste tank
out of the Cassette
toilet by lifting up
the yellow clip.
B. Unscrew the bracket
and take it out.
Bracket
C.
Drain tube has to be pulled out on four places :
1. In the middle (lift up and
pull the tube inside the
Cassette)
2. In the front (take tube out
of the bracket and pull the
tube over the two ribs)
1.
3.
4.
Plug
Sight glass
D.
Will be replaced by :
1. Drain tube + clamp collar
2. Blind plug
* 3. Screw
* 4. Linkage
F.
1.
2.
3.
4.
Push drain tube (1) into the
water tank and push clamp
collar over the tube. Place
sight glass in the plug and
press drain tube into the
bracket.
* Screw and linkage only have to be used when the toilet has been
produced before November 1992. Production date can be found on the
identification label, on the bottom of the waste tank. Model : C2 LH
No. : 1631862 GO 7
Code : 990706
1. 1.
G. Press blind plug (2) into the
hole at the back.
Plug
Sight glass Bracket
Bracket 2.
Note: Some force may be needed
to take the drain tube out
3. In the back (pull the tube
over the rib)
4. Pull sight glass
of plug.
Two ribs
E.
C2, C4
16

*Underneath instructions only have to be followed if the Cassette toilet has been produced before
November 1992 (see identification label). As otherwise water will stay in during winterizing,
the pump will be moved to the left side of the level indicator (from A to B).
The distance from A to B will be around 10cm. Outside view
H.
Take tissue well and
tissue holder out to
get to the location of
the pump.
Tissue well Tissue holder
I. Unscrew the screw
on the pump retainer
and take complete pump
out of the water tank.
Disconnect the
flush tube from
the pump.
J. 3. 4. 5. Nr. 3 (screw) and 4 (linkage) are in the package.
Nr. 5 is the screw from the pump (see I, photo 1).
K.
Place the linkage above the pump retainer
and screw the two together from the
underside upwards with screw nr.5.
Note: make sure that the linkage is
placed on the pump retainer as
positioned on the photo with nr.4 (J).
L.
A.B.
Connect flush tube back onto
the pump and place the pump
on the left side of the level
indicator and screw the linkage
on the place where the pump
was assembled in the first
place. Screw nr. 3 has to be used.
M.Place tissue holder and
tissue well back into
the water tank.
Leaflet no. 21374/062001
Pump retainer
**As the screwing may need some force,
be careful for injuries on hands and
fingers.
17

13/07/2006 Description: C2 C3 C4
C200 Automatic Vent
13/07/2006Date:
-Tools required:
V2Version:
Description: C2 C3 C4 C200 Automatic vent
Part number: 23722-74
Look for Service Centers, Point of Sale addresses and other
information on: www.thetford-europe.com
A
B
Repair instruction
Holding tank
C2/C3/C4/C200
Turn the automatic vent
to the left and take it
out.
CPlace new automatic
vent in the waste tank
and turn it to the right
to lock it in the waste
tank.
18

21322 Float arm
1. Cassette C2/C3/C4
Note : If the float retainer is still in the waste tank (float arm has fallen off), the new float arm can not be
assembled. Float retainer has to be taken out first. This can be done with a small flat screwdriver.
As the waste tank is welded, this can only be done through the hole in the middle.
Inside view to take the
float retainer out.
Place screwdriver
between rib and float
retainer and lift it up.
A.
B.
For placing the new
float arm, take sliding
cover off, open the
blade and go with
your hand in the
waste tank.
Float arm
Float retainer
Magnet always has to
point to the outside of
the waste tank.
C. Inside view
waste tank. Place where float arm has
to be assembled Press the
float retainer
in.
Position float arm,
view from the outside.
Float arm is always
assembled on the
opposite side of the
blade opener.
Magnet pointed
to the outside
Blade opener
Sliding cover
19