FORM: 2391 DRAWING NO: ICA-525C-38-00001 Cessna Aircraft ...

FORM: 2391DRAWING NO: ICA-525C-38-00001 Cessna Aircraft Company P.O Box 7704 WICHITA, KS 67277

ENGINEERING DRAWING AND PART LIST SIGNATURE AUTHORIZATION Originals Electronically Signed in the VPM System

================================================================================REVISION: ICA-525C-38-00001 REPORT ---

PKG: 0000015958 ================================================================================ ORIGINATOR Mike Barrett (APPROVE 06/29/2012 13:02:41) GROUP Mike Barrett (APPROVE 07/03/2012 15:09:16) FATIGUE Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) M&P Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) STRESS Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) ELECTRICAL ME Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) ME Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) GROUP Mike Barrett (APPROVE 07/03/2012 15:09:35) AES_SYS Matthew Noftsger (APPROVE 07/03/2012 14:27:20) MECH SYSTEMS-ECS Chris McDaniel (APPROVE 06/29/2012 14:17:42) PROJECT Jim Frickey (APPROVE 07/03/2012 14:44:12) SECTION Mike Barrett (APPROVE 07/03/2012 15:10:06) WEIGHTS Mike Barrett (NOT REQUIRED 07/03/2012 15:09:31) RELEASE Peggy Pierce (APPROVE 07/03/2012 15:12:25)

For

CESSNA AIRCRAFT COMPANY

AIRCRAFT DIVISION

WICHITA, KANSAS 67277

Model 525C Externally Serviced Toilet System

ICA Supplement

MODEL NO: 525C

REPORT NO: ICA-525C-38-00001

REPORT DATE: 06/29/12

Cessna Aircraft Company Page 2

P.O. Box 7704 Model 525C Externally Serviced Toilet System ICA Supplement Wichita, Kansas 67277 Report No.: ICA-525C-38-00001 Rev -

REVISIONS

Rev Date By Approved By

- See Title Page Mike Barrett See Separate Electronic Signature Page

ECR 072549

Section Description

ALL Initial Release



CONTENTS

Section / Title Page

1.0 INTRODUCTION .............................................................................................................................. 5

1.1 Purpose .............................................................................................................. 5

2.0 APPLICABILITY ............................................................................................................................... 6

2.1 Effectivity ............................................................................................................ 6

2.2 Complete ICA Documents ................................................................................... 6

3.0 DESCRIPTION AND OPERATION .................................................................................................. 7

3.1 General ............................................................................................................... 7

3.2 Description .......................................................................................................... 7

3.3 Operation ............................................................................................................ 9

3.4 Servicing ............................................................................................................. 9

3.5 System Component(s) .......................................................................................13

3.6 System Wiring ....................................................................................................14

4.0 REMOVAL AND INSTALLATION .................................................................................................. 15

4.1 Externally Serviceable Flush Toilet - Removal/Installation .................................15

4.2 Toilet Waste Drain/Water Hose - Removal/Installation .......................................19

4.3 Toilet Waste Drain Valve - Removal/Installation .................................................23

4.4 Toilet Monitor Switch - Removal/Installation .......................................................26

4.5 Toilet Monitor Light Emitting Diode (LED) - Removal/Installation .......................29

4.6 Toilet Heater Gasket - Removal/Installation .......................................................32

4.7 Externally Serviceable Toilet access Door - Removal/Installation ......................35

5.0 MAINTENANCE AND SPECIAL TOOLS ....................................................................................... 38

5.1 Maintenance ......................................................................................................38

5.2 Special Tools .....................................................................................................38

6.0 TESTING, RETURN TO SERVICE, AND REPAIR ....................................................................... 39

6.1 Repair ................................................................................................................39

6.2 Troubleshooting .................................................................................................40

7.0 AIRWORTHINESS LIMITATIONS ................................................................................................. 42

7.1 Limitations and Replacement Intervals ...............................................................42



FIGURES

Figure / Title Page

Figure 3-1: Toilet and Service Panel .........................................................................................13

Figure 4-1: Toilet and Serivce Panel .........................................................................................18

Figure 4-2: Toilet and Service Panel .........................................................................................22

Figure 4-3: Toilet Waste Drain Valve .........................................................................................25

Figure 4-4: Toilet Monitor Switch Installation .............................................................................28

Figure 4-5: Toilet Monitor Light Emitting Diode..........................................................................31

Figure 4-6: Toilet Heater Gasket Installation .............................................................................34

Figure 4-7: Externally Serviced Toilet Access Door ...................................................................37

Figure 7-1: Wiring Diagram .......................................................................................................43

Figure 7-2: Wiring Diagram .......................................................................................................44

TABLES

Table / Title Page

Table 2-1: Installation ICA Effectivity .......................................................................................... 6

Table 3-1: Tools and Equipment ...............................................................................................10

Table 3-2: Ethylene Glycol Mixture ............................................................................................12

Table 6-1: Parts List ..................................................................................................................39



1.0 INTRODUCTION

1.1 Purpose

1.1.1 The purpose of this Instruction for Continued Airworthiness Supplement is to

provide the maintenance technician with the information necessary to ensure the

correct functionality and performance of the Externally Serviced toilet system on

the 525C aircraft.

1.1.2 This supplemental document is designed to satisfy the required 14 CFR 23.1529

“Instructions for Continued Airworthiness” requirements associated with this

installation. This document is a supplement to the Model 525C Maintenance

Manual and may or may not be incorporated.

1.1.3 If this information is incorporated into the Model 525C Maintenance Manual, the

maintenance manual shall take precedence over this supplemental document.

Refer to the applicable ATA chapter and section of the respective Maintenance

Manual for the status of all ICA Supplements applicable to your model.

NOTE: This document must be placed with the aircraft operator’s Technical Library CD-

ROM or Maintenance Manual and incorporated into the operator’s scheduled

maintenance program.



2.0 APPLICABILITY

2.1 Effectivity

This Instruction for Continued Airworthiness (ICA) supplement is effective for the following

aircraft model(s) and serialization where this Externally Serviced Toilet system is installed:

Table 2-1: Installation ICA Effectivity

2.2 Complete ICA Documents

2.2.1. The following document(s), in conjunction with this supplement, constitute the

Instructions for Continued Airworthiness for the Externally Serviced Toilet system.

All items must be available to the operator at initial delivery.

Model 525C Wiring Diagram Manual (CJ4-0001 and On)

Model 525C Maintenance Manual

Aircraft Technologies Component Maintenance Manual (ZZ-CJ4-EX)

Model Beginning

Effectivity

Ending

Effectivity

525C -000100 -and On



3.0 DESCRIPTION AND OPERATION

3.1 General

A. This section provides maintenance information for the externally serviceable

flush toilet. The unit is a compact, electrically operated flush toilet which utilizes

ordinary tap water, and a germicidal deodorant and is serviceable with a portable

ground unit.

B. Prior to flight the flush toilet holding tank is precharged with water-chemical

solution. During use of the toilet, waste is flushed, using this water-chemical

solution, into the toilet’s holding tank. During toilet ground servicing, a ground

service unit is connected to the airplane’s waste drain valve at the service panel,

toilet waste is disposed of through the waste hose, and fresh water-chemical

solution is pumped into the toilet through the water fill hose.

C. Prior to removal of the toilet assembly, it must be serviced externally and empty

of any waste and water-chemical solution.

3.2 Description

A. Externally Serviceable Flush Toilet

1) The toilet is located in the aft cabin compartment on the left side of the

airplane between FS 336.80 and FS 355.20. The toilet is a dual tank,

non-recirculating type. The toilet is attached in a structural frame and

consists of a cabinet top lid/deck and seat cushion. The toilet cabinet

houses a fresh water tank and a grey water tank that are separated from

each other by a tank liner. The toilet deck consists of the toilet seat and

bowl, a counterweighted flapper valve, and the flush switch. The deck is

hinged on the outboard side and is equipped with an over center latch on

the inboard edge. A small drain/vent line is attached to the toilet cabinet

and routes through the aft cabin skin and to the aft fairing drain mast.

B. Fresh Water Tank

1) Common to the fresh water tank is the flush pump, fresh water float

switch and flush circuit plumbing. The flush pump is controlled by the

flush switch located on the outboard top surface of the deck.

C. Grey Water Tank



1) The main component of the grey water tank is the macerator pump. This

pump is controlled by the switch located at the service panel.

D. Service Water Distribution

1) The servicing system plumbing consists of four separate hose assemblies

that connect the toilet to the external service panel. Two of these hose

assemblies are common to the fresh water side, and the other two hose

assemblies are common to the waste water side. The fresh water side of

this system consists of a distribution block and three discrete nozzles.

The fresh water system is equipped with a solenoid valve that is

controlled by the float switch in the fresh water tank. One fresh water

hose connects between the toilet cabinet and a bulkhead fitting located

on the left side of the aft pressure bulkhead. The other fresh water hose

connects at the other end of the same bulkhead fitting and routes to the

fresh water port at the toilet service access door. One waste water hose

connects between the toilet cabinet and a aft pressure bulkhead fitting

which is located near the fresh water aft pressure bulkhead fitting. The

other waste water hose connects at the other end of the aft pressure

bulkhead fitting and routes to the service panel waste valve.

E. External Toilet Service Access Door

1) The external toilet service door is located on the right aft fairing of the

fuselage, below the engine nacelle between FS 389.44 and FS 404.97.

The service access door opens to expose the waste service valve

assembly, a fresh water service connection, Fill/Drain switch and

indicators.

2) The waste valve is a dual door type that is fully opened only after the

service cart hose is connected. After completing the servicing of the toilet

system, the outer door is closed, and in doing so, the inner door is closed

as well.

3) The fresh water quick disconnect port is equipped with a cap and lanyard

assembly to cover the port when not in use.



4) The control switch is a three position momentary type switch that is

normally closed.

5) The Fill/Drain switch is the solitary control switch for the system at the

service panel. This switch is a guarded switch which centers the switch in

the off position any time the guard is closed. The service access door is

equipped with a block that will close the switch guard (turning the switch

to OFF) any time the service access door is closed. Attached to the inside

surface of the access door are service instruction placards and attached

to the door itself are labels for each of the switch positions and indicators.

3.3 Operation

A. The flush cycle is initiated by pressing the PRESS TO FLUSH button located on

the upper outboard surface of the deck. When the flush button is depressed it

energizes a circuit in the timer box located on the outside front wall of the toilet

cabinet. The timer box limits the run time of the flush pump to two seconds. As

the flush pump runs, it draws water out of the fresh water tank, through the flush

circuit plumbing, and into the toilet bowl. Water that flows into the bowl is

deposited directly into the grey water tank. After the timer box senses the two

second interval has elapsed, it removes power from the flush pump and resets

itself for the next time the flush button is depressed. The fresh water tank has a

limited capacity. The toilet is limited to 15 flushes per servicing. After the water in

the fresh water tank is exhausted, the toilet can no longer be flushed until the

toilet is serviced.

3.4 Servicing

A. The flush toilet should be serviced during routine ground maintenance of the

airplane following any usage. It is more efficient and convenient to service the

toilet on a regular basis than to wait until the tank is filled to capacity.



B. Tools and Equipment

NOTE: Equivalent substitutes may be used for the following items.

Table 3-1: Tools and Equipment

NAME NUMBER MANUFACTURER USE

Disinfectant

Lysol Spray

Commercially Available To disinfect toilet.

Germicidal

Deodorant

ChemKare Monogram Sanitation, 800 W.

Artesia Blvd. Compton, CA

90224

As tank precharge

mixture.

Blue Lagoon Arrow-Magnolia, 2646 Rodney

Lane. Dallas, TX 75229

As tank precharge

mixture.

Ethylene Glycol

Anti-Freeze

Commercially Available To prevent

precharge mixture

from freezing.

Toilet Ground

Service Cart

10-4036-

0010

Tronair, S. 1740 Eber Rd.

Holland, OH 43528

To drain clean, and

recharge toilet.

C. Servicing Toilet (refer to Figure 3-1).

1) Waste Removal and Recharge

a) Open airplane exterior service panel door.

b) Remove protective cap from water fill port.

c) Open waste valve outer door.

d) Connect water fill hose and waste drain hose from ground service

unit to airplane service panel connections.

e) Push on the Push to Open Lever for the inner door of the waste

valve.



f) Open the release valve on the servicing cart.

NOTE: This will allow the fill fluid to drain back into the service cart

fill tank.

g) To drain waste, push and hold Fill/Drain switch inboard to DRAIN

position for a maximum of 15 seconds.

NOTE: Green service panel light is on

h) Release switch after 15 seconds or when flow has stopped.

i) To recharge fresh water tank and rinse waste system, pull

Fill/Drain switch outboard to FILL position.

NOTE: Green service panel light is on

j) Charge the toilet tank until the amber service panel light comes

on.

k) Push and hold switch to DRAIN position for a maximum of 5

seconds to drain residual rinse water.

l) Close switch guard and make sure both indicator lights are off.

m) After approximately one to two minutes, disconnect the hose. This

will let the residual servicing water drain into the service cart and

prevent a spill.

n) Disconnect water fill hose and waste drain hose from airplane

service panel connections.

o) Replace water filler cap and close outer waste drain valve door,

which in turn closes the inner flapper door.

p) Close and secure airplane exterior toilet service panel door.

NOTE: During freeze conditions, add ethylene glycol with an

antifoam agent to the flush fluid. Do not use antifreeze chemicals

with a stop-leak agent, which will not mix correctly with the

deodorizing toilet precharge-chemicals.



Table 3-2: Ethylene Glycol Mixture

Ethylene glycol freezing point vs. concentration in water

Weight Percent EG (%) Freezing Point (deg F) Freezing Point (deg C)

0 32 0

10 25 -4

20 20 -7

30 5 -15

40 -10 -23

50 -30 -34

60 -55 -48

70 -60 -51

80 -50 -45

90 -20 -29

100 10 -12

http://www.xydatasource.com/xy-showdatasetpage.php?datasetcode=746841&searchtext=glycol&dsid=34



Figure 3-1: Toilet and Service Panel



3.5 System Component(s)

A. Components

1) CJ4-2012EX-0001 Toilet – The toilet is installed in the LH aft cabin

opposite the escape hatch.

2) Timer Box – this component as attached to the outside of the toilet

cabinet with fabric fastener. It is attached to the toilet electrically with a

connector and to the airplane with a connector. All external electrical

connections to the toilet go through the timer box, however only the flush

circuit actually interfaces directly with the timer circuit in the box.

3) Macerator Pump – This component attached to the inside surface of the

grey water tank by two clamps. It pumps out the material in the grey

water tank when activated at the service panel.

4) Flush Pump – This component is attached to the inside surface of the

fresh water tank by a bracket and clamp. It pumps water out of the fresh

water tank to the toilet bowl.

5) Float Switch – This component is attached to the inside wall of the fresh

water tank by a bracket and screw. This component monitors the fluid

level in the fresh water tank and controls the activation of the solenoid

valve and the “full” indicator LED.

6) Flush Button – This component is screwed directly to the toilet deck. It

controls the activation of the timer box which controls the flush circuit.

3.6 System Wiring

Refer to the Model 525C Wire Diagram Manual (CJ4-0001 and On) for electrical wiring.

Figure 3-2 and 3-3 shows the wire diagram for the Externally Serviced Toilet System.



4.0 REMOVAL AND INSTALLATION

NOTE: If applicable, make sure that the aircraft is configured for maintenance as defined

by the associated system in the maintenance manual or in this document,

including the removal of electrical power, avionics power, hydraulic power, etc.,

prior to removal or installation of aircraft components.

4.1 Externally Serviceable Flush Toilet - Removal/Installation

A. General

1) The externally serviceable flush toilet is located in the aft cabin

compartment on the LEFT side of the airplane between FS 336.80 and

FS 355.20.

2) Prior to removal of the toilet assembly, it must be serviced externally and

be empty of any flushing fluid or water. Refer to Servicing, para 3.4 of this

supplement.

3) A placard with service instructions is located on the external toilet service

door.

B. Remove Externally Serviceable Toilet (refer to Figure 4-1)

1) Remove all of the fluid from the externally serviceable flush toilet. Refer to

Servicing para 3.4 of this supplement.

NOTE: Do not recharge toilet at this time.

2) Remove external electrical power from the airplane.

3) Open the tailcone baggage compartment door.

4) Open the aft baggage compartment panels 311ATC and 311CTC to

access to the RH aft power junction box (J-Box). Refer to the 525C

Maintenance Manual, Chapter 6-40-00, Access Plates and Panels

Identification – Description and Operation.

5) Disengage the TSP CONTROL (TOILET) (HZ070) circuit breaker and the

TOILET SERVICE POWER (HZ072) circuit breaker.

6) Remove the maintenance cover below toilet seat.

7) Place a small container below connection points to collect any residual

fluid.

8) Disconnect the electrical plug (PZ006) from toilet cabinet.



9) Disconnect the water fill hose (small diameter hose). Direct any residual

fluid into the small container.

10) Disconnect the waste hose (large diameter hose). Direct any residual fluid

into the small container.

11) Plug the open hoses.

12) Remove the small container and dispose of any residual fluid.

13) Remove the toilet seat cushion and seat belts.

14) Lift the toilet bowl seat assembly/deck lid.

15) Remove the four screws attaching toilet assembly to frame assembly.

16) Remove the toilet by lifting straight up and out of frame assembly.

NOTE: Any fluid from the toilet assembly must be wiped immediately.

C. Install Externally Serviceable Toilet (refer to Figure 4-1)

1) Place the toilet assembly in frame assembly.

2) Secure the toilet assembly to frame assembly with four screws.

3) Lower the toilet bowl seat assembly/deck lid.

4) Remove the plug from water fill hose.

5) Apply (A1637-16) anti-seize to connector fitting.

6) Connect and torque water fill hose to toilet assembly. Refer to Model

525C Maintenance Manual, Chapter 20-10-30, Tubing, Hose and Fittings

- Maintenance Practices.

7) Remove the plug from waste hose.


9) Connect and torque water fill hose to toilet assembly. Refer to Refer to

Model 525C Maintenance Manual, Chapter 20-10-30, Tubing, Hose and

Fittings - Maintenance Practices.

10) Connect the electrical plug (PZ006) to toilet assembly.

11) Engage the TSP CONTROL (TOILET) (HZ070) circuit breaker and the

TOILET SERVICE POWER (HZ072) circuit breaker in RH aft power

junction box (J-Box).

12) Open the external toilet service access door. Refer to Model 525C


Identification - Description and Operation.



13) Connect the ground service unit to service panel and charge system with

clean water. Refer to Servicing para 3.4 of this supplement.

14) Check for water leaks around water inlet hose connections.

15) Remove the ground service unit.

16) Set the BATTERY switch on the ELECTRICAL POWER switch panel in

the cockpit to the ON position.

17) Activate the toilet flush switch 12 flush cycles.

18) Service the toilet. Refer to Servicing para 3.4 of this supplement.

19) Set the BATTERY switch on the ELECTRICAL POWER switch panel in

the cockpit to the OFF position.

20) Install the maintenance cover below toilet seat.

21) Install the toilet seat cushion and seat belts.

22) Close the aft baggage compartment panels 311ATC and 311CTC. Refer

to Model 525C Maintenance Manual, Chapter 6, Access Plates and

Panels Identification - Description and Operation.

23) Close the tailcone baggage compartment door.



Figure 4-1: Toilet and Serivce Panel



4.2 Toilet Waste Drain/Water Hose - Removal/Installation

A. General

1) The forward Toilet Waste Drain/Water Hoses are located at the aft

pressure bulkhead in the aft cabin compartment. The aft Toilet Waste

Drain/Water Hoses are located at the aft pressure bulkhead below the aft

baggage compartment floor.

2) Prior to removal of the Toilet Waste Drain/Water Hoses, it must be

serviced externally and be empty of any flushing fluid or water. Refer to



door.

B. Remove Forward Toilet Hoses (refer to Figure 4-2)

1) Remove the electrical power from the airplane.



3) Remove the maintenance cover below toilet seat

4) Disconnect the clean water forward toilet hose at the toilet assembly and

the aft pressure bulkhead.

5) Remove tie straps that attach the hose as necessary.

6) Remove the forward toilet hose from the airplane.

C. Install Forward Toilet Hoses (refer to Figure 4-2)

1) Put the forward toilet hose in its position in the airplane.


3) Connect and torque forward toilet hose to toilet assembly. Refer to Model

525C Maintenance Manual, Chapter 20-10-30, Tubing, Hose and Fittings-

Maintenance Practices.

4) Install tie straps.


6) Do the servicing of the externally serviceable flush toilet. Refer to


7) Make sure that there are no leaks.



8) Install the maintenance cover below toilet seat.

D. Remove Aft Toilet Hoses (refer to Figure 4-2)

1) Remove the electrical power from the airplane.



3) Remove the aft baggage compartment floor panels 312CR, 311CL and

311AC, Refer to Model 525C Maintenance Manual, Chapter 6-40-00,

Access Plates and Panels Identification- Description and Operation.

4) Disconnect the aft toilet hoses at the aft pressure bulkhead.

5) Remove tie straps and clamps that attach the hoses as necessary.

6) Open the external toilet service access door.

7) Remove the waste drain valve. Refer to Waste Drain Valve Removal para

4.3 of this supplement.

8) Through the waste drain opening, disconnect the aft water hose from

service panel and remove from airplane.

9) Remove the hose from the airplane.

E. Install Aft Toilet Hoses (refer to Figure 4-2)

1) Put the aft water hose in its position in the airplane.

2) Apply (A1637-16) anti-seize to connector fittings.

3) Connect and torque aft water hose to service panel fitting and aft

pressure bulkhead. Refer to Model 525C Maintenance Manual, Chapter

20-10-30, Tubing, Hose and Fittings-Maintenance Practices.

4) Install tie straps and clamps.


6) Connect the aft waste drain hose to aft pressure bulkhead fitting and

torque. Refer to Model 525C Maintenance Manual, Chapter 20-10-30,

Tubing, Hose and Fittings-Maintenance Practices.

7) Install the waste drain valve. Refer to Waste Drain Valve Installation para







10) Install the aft baggage compartment floor panels 312CR, 311CL and

311AC. Refer to Model 525C Maintenance Manual, Chapter 6-40-00,

Access Plates and Panels identification- Description and Operation

11) Close the external toilet service access door.



Figure 4-2: Toilet and Service Panel



4.3 Toilet Waste Drain Valve - Removal/Installation

A. General

1) The toilet waste drain valve is located inside the Toilet Service Access

Door on the right side of the airplane between FS 389.44 and FS 404.97.

2) Prior to removal of the toilet waste drain valve, the toilet must be serviced

externally and be empty of any flushing fluid or water. Refer to Servicing

para 3.4 of this supplement.


door.

B. Remove Waste Drain Valve (refer to Figure 4-3)




3) Open the external toilet service access door

4) Remove the eight screws that attach the waste drain valve to the toilet

service panel and the toilet drain adapter.

5) Carefully pull the waste drain valve and adapter out of service panel far

enough to access aft waste drain hose adapter fitting.

6) Disconnect the aft waste drain hose from the drain adapter fitting.

7) Remove the O-ring from the waste drain valve.

8) Remove the heater gasket (TY006) from the waste drain valve. Refer to

Heater Gasket Removal para 4.6 of this supplement.

C. Install Waste Drain Valve (refer to Figure 4-3)

1) Apply a thin coat of silicone grease (5565450-28) to the surface of a new

O-ring.

2) Install the new O-ring on the waste drain valve. Refer to Model 525C

Maintenance Manual, Chapter 20-10-15, Packing and Backup Ring -


NOTE: The O-ring is approximately 1 inch (25.4 mm) smaller in diameter

than the waste drain valve.

3) Install new heater gasket (TY006) on the waste drain valve. Refer to

Heater Gasket Installation para 4.6 of this supplement.




5) Connect aft waste drain hose to drain adapter fitting and torque. Refer to

Model 525C Maintenance Manual, Chapter 20-10-30, Tubing, Hose and

Fittings – Maintenance Practices.

6) Put the waste drain valve in its position on the airplane.

7) Install the eight screws that attach the waste drain valve to the toilet

service panel and the toilet drain adapter.







Figure 4-3: Toilet Waste Drain Valve



4.4 Toilet Monitor Switch - Removal/Installation

A. General

1) The externally serviceable flush toilet monitor switch is located inside of

the Toilet Service Panel.

B. Remove Toilet Monitor Switch (refer to Figure 4-4)


2) Open the tailcone baggage compartment door. Refer to Model 525C



3) Open aft baggage compartment panels 311ATC and 311CTC to access

the aft power junction box (J-Box). Refer to Model 525C Maintenance

Manual, Chapter 6-40-00, Access Plates and Panels Identification -

Description and Operation.

4) Disengage the TSP CONTROL (TOILET) (HZ070) and TOILET SERVICE

POWER (HZ072) circuit breakers on the aft J-Box.


6) Remove the screws that attach the bracket to the pan.

7) Pull the bracket away from the pan to get access to the monitor switch

(SY008) electrical wires.

8) Tag and disconnect the electrical wires from the switch. Refer to Wiring

Diagram, Figure 7-1.

9) Remove the nut, lock washer that attach the switch to the switch guard

and the bracket.

10) Remove the switch, key washer, and switch guard from the bracket.

11) Remove the switch and the key washer from the airplane.

C. Install Toilet Monitor Switch (refer to Figure 4-4)

1) Put the monitor switch (SY008), key washer, and switch guard in their

position at the bracket.

2) Install the lock washer and the nut.

3) Remove the tags and connect the electrical wires to the switch. Refer to

Wiring Diagram, Figure 7-1.

4) Install the screws that attach the bracket to the pan.



5) Engage the TSP CONTROL (TOILET) (HZ070) and TOILET SERVICE


6) Apply electrical power to the airplane.

7) Open the switch guard.

8) Put the switch in the FILL position.

NOTE: The amber (full) indicator light blinks briefly and the green (system

on) light is illuminated.

9) Put the switch in the OFF position.

NOTE: Both indicators will be off.

10) Momentarily put the switch in the DRAIN position.

NOTE: The amber (full) indicator light blinks briefly and the green (system

on) light is illuminated.

11) Put the switch in the OFF position.

NOTE: Both indicators will be off.

12) Close the switch guard.

13) Close the externally serviced toilet door.

14) Close aft baggage compartment panels 311ATC and 311CTC. Refer to

Model 525C Maintenance Manual, Chapter 6-40-00, Access Plates and


15) Close the tailcone baggage compartment door. Refer to Model 525C





Figure 4-4: Toilet Monitor Switch Installation



4.5 Toilet Monitor Light Emitting Diode (LED) - Removal/Installation

A. General

1) This section gives the removal and installation procedures for the light

emitting diode (LED) (FY014, Green - System On and FY016, Amber -

FULL). The LED is located inside of the Toilet Service Panel.

B. Remove Toilet Monitor Light Emitting Diode (refer to Figure 4-5)

NOTE: The removal of the LED is typical.









4) Disengage the TSP CONTROL (TOILET) (HZ070) and TOILET SERVICE


5) Open the externally serviced toilet door.

6) Remove the screws that attach the bracket to the pan.

7) Pull the bracket away from the pan to get access to the monitor LED

(FY014 and FY016) splices (AY032, AY034, and AY036).

8) For the green monitor LED (FY014), tag and disconnect the splices

(AY032 and AY036) from the LED. Refer to Wiring Diagram, Figure 7-1.

9) For the amber monitor LED (FY016), tag and disconnect the splices

(AY034 and AY036) from the LED. Refer to Wiring Diagram, Figure 7-1.

10) Remove the monitor LED from the bracket.

C. Install Toilet Monitor Light Emitting Diode (refer to Figure 4-5)

NOTE: The installation of the LED is typical.

1) Put the monitor LED (FY014 and FY016) in its position at the bracket.

2) For the green monitor LED (FY014), remove the tags and connect the

splices (AY032 and AY036) to the LED. Refer to Wiring Diagram, Figure

7-1.



3) For the amber monitor LED (FY016), remove the tags and connect the

splices (AY034 and AY036) to the LED. Refer to Wiring Diagram, Figure

7-1.

4) Install the screws that attach the bracket to the pan.

5) Engage the TSP CONTROL (TOILET) (HZ070) and TOILET SERVICE


6) Do the monitor LED operational check. Refer to Operational Check, para


7) Close the externally serviced toilet door.









Figure 4-5: Toilet Monitor Light Emitting Diode



4.6 Toilet Heater Gasket - Removal/Installation

A. General

1) This section gives the removal and installation procedures for the Heater

Gasket (TY006).

2) The Heater Gasket is installed on the toilet waste drain valve located

inside the Toilet Service Panel on the RIGHT side of the airplane between

FS 389.44 and FS 404.97.

3) Prior to removal of the Heater Gasket, the toilet must be serviced

externally and be empty of any flushing fluid or water. Refer to Servicing,


4) A placard with service instructions is located on the external service

panel.

B. Remove Toilet Heater Gasket (refer to Figure 4-6)


Servicing, para 3.4 of this supplement.









5) Disengage the DRAIN HEATERS (HZ057) circuit breaker.


7) Remove the waste drain valve. Refer to Waste Drain Valve Removal,


8) Tag and disconnect the splices (AY038 and AY040) from the Heater

Gasket. Refer to Wiring Diagram, Figure 7-1.

9) Remove the heater gasket (TY006).

C. Install Toilet Heater Gasket (refer to Figure 4-6)

1) Install new heater gasket (TY006) on the waste drain valve.



2) Remove the tags and connect the splices (AY038 and AY040) from the

Heater Gasket. Refer to the Wiring Diagram, Figure 7-1.

3) Install the waste drain valve. Refer to Waste Drain Valve Installation, para


4) Engage the DRAIN HEATERS (HZ057) circuit breaker.


Servicing, para 3.4 of this supplement..











Figure 4-6: Toilet Heater Gasket Installation



4.7 Externally Serviceable Toilet Access Door - Removal/Installation

A. General

1) This section gives the removal and installation procedures for the

externally serviceable toilet access door.

B. Remove Externally Serviceable Toilet Access Door (refer to Figure 4-7)

1) Open the externally serviceable toilet access door.

2) Remove and discard the cotter pin from the bottom hinge bolt.

3) Remove the nut, washers, and bolt from the bottom hinge.

4) Remove and discard the cotter pin from the top hinge bolt.

5) Remove the nut, washers, bonding jumper, and bolt from the top hinge.

6) Remove the externally serviceable toilet access door from the airplane.

7) If necessary, remove the bonding jumper.

8) Remove and discard the tiedown strap from the bonding jumper and the

top hinge.

9) Remove the nut, washer, and screw from the bonding jumper and the top

hinge.

10) Remove the bonding jumper.

C. Install Externally Serviceable Toilet Access Door (refer to Figure 4-7)

1) If necessary, install the bonding jumper.

2) Put the bonding jumper in its position on the top hinge.

3) Install the screw, washer, and nut that attach the bonding jumper to the

top hinge.

4) Install the tiedown strap that attaches the bonding jumper to the top

hinge.

5) Put the externally serviceable toilet access door in its position.

6) Install the bolt, washer, bonding jumper, and nut in the top hinge.

7) Install the new cotter pin in the top hinge bolt. Refer to Model 525C

Maintenance Manual, Chapter 20-10-10, Safetying - Maintenance

Practices.

8) Do an electrical bond check between the externally serviceable toilet

access door and the airplane structure. Refer to Model 525C

Maintenance Manual, Chapter 20-30-30, Electrical Bonding -




NOTE: Bonding should be less than 0.03 Ohms.

9) Close and latch the externally serviceable toilet access door.

10) Make sure that there is no overlap between the door and the adjacent

structure.

11) Release the latch assemblies.

12) Make sure that the latches do not touch the door skin.

13) Make sure that the door opens freely and does not touch the adjacent

structure.

14) Close and latch the door.



Figure 4-7: Externally Serviced Toilet Access Door



5.0 MAINTENANCE AND SPECIAL TOOLS

5.1 Maintenance

The installation of the Toilet and the Toilet Service system on the Model 525C has no

manufacturer specified (required and/or recommended maintenance task) requirements

for continued airworthiness.

5.2 Special Tools

Other than the standard shop aids (tool & test equipment), there are no manufacturer

specified special tools and/or test equipment required for the installation of the Toilet or

the Toilet Service system on the Cessna Model 525C aircraft.



6.0 TESTING, RETURN TO SERVICE, AND REPAIR

6.1 Repair

A. General

1) Refer to Table 6-1 for a list of parts for the Externally Serviced Toilet

System. To obtain a copy of supplier publication, refer to supplier

publications in the Model 525C Maintenance Manual - Introduction,

Supplier Publication List.

Table 6-1: Parts List

CJ4-2012EX-001 Toilet Assy 1

MS27039-1-21 Screw A 4

Nas1149F0332P Washer A 4

4711672-23 Frame assy-Toilet 1

AE721131-1 Hose Assy-Water Fwd 1

AN837-8J Elbow 1

NAS1149C1232R Washer A 1


AN924-8J Nut A 1

AE721133-1 Hose Assy-Water Aft 1

6219394-9 Cap Assy-Water Inlet 1

AE721132-1 Hose Assy-Waste Drain Fwd 1

AN837-16J Elbow 1



AN924-16J Nut A 1

AE721134-1 Hose Assy-Waste Drain Aft 1

7114131-2 Connector-Waste Drain Hose 1



AN924-16J Nut A 1



10101B533 Valve-Waste Drain 1

7114131-1 Adapter-Waste Drain 1

MS28775-231 O-Ring A 1

HG101 Gasket-Heater TY006 A 1

MS27039C1-12 Screw A 8

2TL11-5 Switch-Toggle Fill/Drain SY008 1

MS25214-2 Guard-Switch 1

SP100501-A Light-LED Amber FY014 1

SP100501-G Light-LED Green FY016 1

7110232-9 Support-Switch 1

MS27039-1-08 Screw A 4

7110231-2 Door Assy-Toilet Access 1

AN3-5 Bolt A 2

NAS1149F0332P Washer A 4

MS17825-3 Nut A 2

MS24665-132 Pin-Cotter A 2

6910215-4 Hinge- Door Upper And Lower 2

MS25083-2BB5 Jumper Assy 1

MS2039-1-10 Screw A 1

NAS114900332J Washer A 1

MS21042-3 Nut A 1

6.2 Troubleshooting

A. General

1) Refer to supplier publication for troubleshooting, maintenance, repair, and

adjustment/test instructions for the toilet assembly and its components.

To obtain a copy of supplier publication, refer to supplier publications in

the Model 525C Maintenance Manual - Introduction, Supplier Publication

List.



NOTE: An understanding of the toilet assembly components operation

and circuitry is necessary to perform effective troubleshooting. The

suppliers component manual contains a toilet troubleshooting guide.

Toilet assembly troubleshooting is usually tracing a problem to

replaceable components, some of which may be electrical. A thorough

understanding of wiring diagrams and electrical schematics within the

suppliers component maintenance manual will prove invaluable.



7.0 AIRWORTHINESS LIMITATIONS

7.1 Limitations and Replacement Intervals

Cessna Aircraft Company Model 525C Maintenance Manual, Chapter 4, Airworthiness

Limitations, contains the system and airframe limitations for the Model 525C.

NOTE: The Airworthiness Limitations section is FAA-approved and specifies

maintenance required under Section 43.16 and 91.403 of the Code of

Federal Regulations, unless an alternative program has been FAA

approved.

NOTE: There are no new (or additional) airworthiness limitations associated with

this equipment and/or installation.



Figure 7-1: Wiring Diagram



Figure 7-2: Wiring Diagram

FORM: 2391 DRAWING NO: ICA-525C-38-00001 Cessna Aircraft ...

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Transcript of FORM: 2391 DRAWING NO: ICA-525C-38-00001 Cessna Aircraft ...