Thetford C402C/X Toilet Pump Replacement Guide

This document is designed for customer service and technical staff to assist with inquiries, troubleshooting, and guidance on the Thetford C402C/X toilet pump replacement process. It provides a step-by-step instruction on how to replace the pump, ensuring the correct handling and installation to maintain the product's functionality and reliability.

Product Information

• Model: Thetford C402C/X
• Part Number: 16374

Tools Required

• Knife
• Blow-drier
• Wire stripper
• Crimps (Connector pliers)

Replacement Instructions

A. Handle Removal

1. Start by removing the handle from the unit to ensure there is no obstruction during the pump replacement process.

B. Control Panel Removal

2. Carefully remove the control panel to access the internal components of the toilet.

C. Control Well Access

3. Proceed to remove the control well cover to reveal the inside view and gain access to the pump area.

D. Seal and Pump Removal

4. Remove the seal from around the control well to prevent any damage or loss of the seal.
5. Extract the pump from the water tank, preparing it for disconnection.

E. Cable and Wire Preparation

6. Cut the cable just above the pump using the wire stripper, ensuring not to damage the wires.
7. Strip the insulation off the white wire, leaving the blue and brown wires intact.
8. Use the wire stripper to strip the ends of the blue and brown wires, preparing them for connection.

F. New Pump Connection

9. Slide the shrink tube onto the wires of the new pump before making any connections.
10. Connect the wires (blue to blue, brown to brown) using crimps or connector pliers.
11. Position the shrink tube over the connections to ensure a secure and insulated join.

G. Securing the Connection

12. Use the blow-drier to melt the shrink tube, securing the wire connections and preventing any potential short circuits.

H. Pump and Seal Replacement

13. Install the new pump into the water tank, ensuring it is correctly positioned and secure.
14. Replace the seal in the control well to ensure a watertight seal around the control area.

I. Reassembly

15. Reattach the control well cover, ensuring it is securely in place.
16. Replace the control panel, making sure it aligns correctly and functions as expected.
17. Reattach the handle to complete the reassembly process.

Troubleshooting Tips

• No Power to Pump: Ensure all wire connections are secure and the shrink tube is properly melted to prevent any short circuits.
• Pump Not Operating After Replacement: Double-check the wire connections (blue to blue, brown to brown) and ensure the pump is correctly positioned within the water tank.
• Leaks Around Control Well: Verify the seal is properly placed and intact. If the seal is damaged, it may need replacement.

This guide is intended to provide comprehensive instructions and troubleshooting tips for the Thetford C402C/X toilet pump replacement. For further assistance, refer to the manufacturer's guidelines or contact technical support.