Vacuflush repair part 1 plus invaluable "tool" recommendation...

skibum

Well-Known Member
Jul 30, 2007
2,770
Perry Hall, MD
Boat Info
2005 Sundancer 260
Engines
496 Magnum HO
I just spent the last 2 weekends fixing the head. We had the Admiral's kids on board for a couple of weeks and as a going away present they left me a clogged head. It sorta worked for a couple of days after they left, but the suction was not as strong as it usually was. I had to really use it one day, and that was all she wrote. I would step on the pedal and the ball would open, but there was no indication of vacuum.

Part 1, Day 1 - Checking for the "blockage" and an "almost" fix.

Step 1 - Hit pedal and use a coat hanger with a small hook in the end to fish around in the ball. No joy.

Step 2 - Plunger. A friend at the marina, Bernie, lent me a small plunger. It did not work. The plunger was a small 4" diameter plunger. It made sufficient suction, but on 2 occasions flipped inside out. Both times, I got a shower. Needless to say, that didn't work. Oh... Bernie got a chuckle both times. I still gave him another beer though.

Step 3 - Completely empty the bowl. Shortly after hearing Bernie laughing, another marina buddy, Craig, stops by to "help" (and laugh at me). He says, "Why didn't you empty the bowl first?". I gave him a beer and told him that I was just now trying to figure out what I was going to use to do that. He says, "Hang on a second.", and leaves. He comes back with this invaluable head repair tool. Wow! The tip was the perfect shape to form a seal when placed in the hole in the bottom of the head. The first stroke completely emptied the head. I discharged it into a bucket. The next 2 strokes sucked out all of the liquid from the waste hose on the head side of the clog. (Step 3a - swap step 3 and step 2 after ordering my own water blaster from Amazon) Craig didn't laugh at me, so I gave him another beer. Bernie went back to his own boat for that round.

Step 4 - Use a plumbing snake to attempt to clear clog. Drove to the house and and back to pick up a plumbing snake. Couldn't get the damn snake any further up the hose than the coat hanger. Drank my 1st beer of the afternoon.

Step 5 - Disassemble mid berth cabin wall to see WTF was going on here. Got my answer.Sea Ray apparently installed 14' of waste hose to make a 9' run to the tank. Arrrgh! I couldn't believe that I hadn't clogged it on multiple ocassions myself. The hose came off of the head, through the bathroom wall, about 10" in a straight line, into a 10" diameter U bend, straight for about 10", 90 degree bend up 20" or so to another 90 degree bend to port and 6-7' straight back to the tank. The lower 90 degree bend had a kink in the line sufficient to reduce the ID of the hose.

Step 6 - Use reverse flow to clear blockage. Realizing that I had zero chance of fishing the blockage out of the inlet side of the hose, I decided to use the water blaster to reverse flow the clog out. I removed the tank side of the waste hose and managed to pull it back and up over the tank. I went into the head and pulled about 2-1/2' of hose out of the wall and stuck into a bucket. I closed the head door to control any flying debris and took a bucket of clean water into the bilge. I filled up the water blaster, pressed the nozzle up to the waste hose, and gave it a good healthy plunge. There wasn't any back pressure, so I needed a few more shots to fill up the hose. On the last one, I felt back pressure, so I gave it a really hard shot. Success! The next shot went right through. Checked the bucket in the head and a small bit of TP was in there along with a good bit of water. No mess, either.

Step 7 - Get a "false positive" test result. I thought that I had it fixed, so I reconnected both ends of the waste hose and gave it a few test flushes. It worked, but there still wasn't 100% suction. Close, but not as strong as it used to be. I'll take it. Maybe if I just recycle beer in it for a few days, it will clear out any remaining clog material.

Step 8 - Catch up to the number of beers that Bernie and Craig had while I was working and test head for next 12 hours.

Continued in part 2....
 
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Very entertaining. Maybe you need one of these signs posted.
 

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I had our first clog when my son Luke decided to use too much TP this last week. Well it was day 2 of a 10 trip and I had bad visions of being in some of the remote places we intended on going with a head that wasn't going to work. I decided while we were at a marina with water to stick my hose with the spray gun attachment on it in the bowl to blow it through. Luckily that worked and I was back in business. I don't believe that may have worked if it was further back in the hose but I was happy.
 
Vacuflush repair part 2...

Part 2, Day 2 - Maybe the duckbills are clogged?

Step 1 - Pondering the inevitable. After recycling beer for about 12 hours, I start thinking that there is something stuck in the duckbills. The head itself is fine. It was working, but the amount of suction just wasn't right. I waited until after I had my morning coffee, and my breakfast, and then a healthy rum and coke before heading down into the bilge.

Step 2 - I flushed about 20 bowl fulls of fresh water to clear out the waste hose. I then use the water blaster to suck the bowl dry. I was able to discharge it right out of the portlight. Good thing no boats were passing my starboard side just then. Right as I get into the bilge, another buddy from the marina, Paul, stops by to see what I am up to. I tell him what has been up, and he says "Oh yeaaaah... That happened to me. You got something in one of your duckbills now. Just go ahead and take them out and stick your finger in the pump to make sure that something isn't clogging the bellows area, too.". So... he lends me a pair of channel locks to save me a trip to the parking lot and I give him a beer. With a little encouragement, I get the duckbills out. 3 of the 4 are obviously shot. Only one looked like it could make a seal. That must be the reason for the weak suction. I couldn't find anything else clogging the bellows or tank connections.

Step 3 - Call it a day and drink beer until I can come back with a set of duckbills. Bernie, Craig, and Paul continued to drink my beer even though there was no work going on...

Part 3, Day 3 - Gathering duckbills.

I get out of work and head over to West marine to pick up a set of duckbills. I walk in the door, and as usual, one of the sales people offers their help. I tell them that I need duckbills, and he said to follow him. He heads to the correct isle and hands me a set. I look at the paper in my pocket that has the part number on it, and they are the correct ones. The package contains a pair of valves. I need four. I ask him for another set and he looks on the shelf. "We're out of them. We should have more in the next 5 - 10 days or I can order them for you.", he says. I had nothing better to do, so I asked him if they could check the downtown store for me. He calls down there and they had them. He gave them my name. So, I am standing by a pile of brand new waste hose talking to the sales guy. I tell him that I am worried about all of the bends and the kink in the hose installed in my boat. He says, "Just replace it. Its one of the cheapest parts of the boat. $3 a foot, I think.". I said, "Really? Are you sure?". He looks in the catalog hanging on the shelf and says "Yep, $3.99 a foot.". "Ok... I'll change it if the duckbills don't do the trick.", I said. Famous last words... I drive to the other West Marine and procure the 2nd set of duckbills.

Part 4, Day 4 - The changing of the duckbills.

Step 1 - Remove pump motor cover.

Step 2 - Unplug tank level sensor harness and move out of the way.

Step 3 - Unplug pump power connector and move out of the way.

Step 4 - Unplug 2 spade connectors to motor assembly and pressure switch.

Step 5 - Loosen the "valve adapter" that connects the outlet of the pump to the inlet of the tank. The first time I did this, I needed channel locks. This time, I could use just my hands. After it was loose, I pushed the white outlet tube about 1/2" further into its tank fitting to get a little clearance to allow removal of the pump.

Step 6 - Loosen the fitting on the inlet side of the pump. This was easy once I got twisted into the correct position allowing me to get 2 hands on the PVC kitchen sink drain style fitting.

Step 7 - Remove 2 outside bolts holding pump to vacuum generation tank and loosen 2 inner bolts. Remove pump.

Step 8 - Remove / Replace duckbills. Once the pump is in your hand, it is easy to see them and to replace them. At this point, I was immune to the smell and thought of playing with sewage. I just wanted to get 'er done.

Step 9 - Reverse steps 7 - 1 to reinstall pump.

Step 10 - Test system. Get mad that there isn't any real improvement. Drink beer and confirm improper operation of head for 12 hours pondering what to do next.

Part 5, Day 5 - I can't take it any more!!!

Step 1 - Its 9:30 am Sunday morning. I just woke up. I'm making my coffee when all of a sudden I get one of them "I gotta go right now" moments. No way in hell was I gonna make it up the dock to the marina bathroom. Its the head on the boat, a load in the shorts, or a dive overboard. I look down, realize that I am wearing a pair of white shorts, and decide that option A, using the head, was my best choice. I used the smallest amount of TP that I could get away with, crossed my fingers and flushed. Rats!. It started flushing with the same reduced suction as before, slowing to even weaker suction, and finally no suction. 100% clogged again. Freshly fouled this time to boot. I finish making the coffee and made it Irish. Then I made more coffee and made it more Irish. After I was thinking more clearly, I decided to just break down and change the damn hose. After all, I need less than 10' and it is only going to be $40 to replace it.

Step 2 - I grabbed a box cutter, a pair of pliers, and a flash light and went into the elaborate and spacious 260DA mid berth to remove the silicone sealing the area where the waste and water hoses pass through the bulkhead separating the passenger compartment from the engine compartment. Sea Ray must have one hell of a caulk gun. I think they used 5 pounds of silicone in the hole. Some of it actually contributed to the seal. Most of it just made a big lumpy mess. 2 hours later, I was able to remove the last of the silicone holding the hose in place. I used the old water blaster / portlight trick to empty the bowl (I really need to remember to check for traffic next time) and removed the clamps holding the waste hose to the head. I pull the hose off, and only a few drops escape. I took a big wad of paper towels and blocked up the end of the hose. I head off to the bilge, remove the waste hose from the tank inlet, then get into the mid berth. With only minor gymnastics, I manage to pull each end of the waste hose into the midberth. Nothing spills into the boat. I coil up the hose, take it out onto the dock, and toss it there in disgust.

Step 3 - NEVER believe what a salesman tells you. I head out to West Marine again. The weather has been lousy all weekend. Good thing, my really bad mood might have been truly foul if I was missing out on prime boating weather. I walk in the store and head off to the hose isle. The same salesman that quoted me the $3.99 price helps me out and I have him cut an 11' section of it for me. I go by the allow 10-20% for waste theory when purchasing materials. I walk up to the checkout and the young lady looks it up and says, "$9.95 per foot.". "What?", I said. She spins the catalog around and points. Sure enough. $9.95 per foot. Normally, $100 wouldn't bother me, but I am on my 5th day, I've already spent over $50 in parts, and I'm in an Irish frame of mind. "Well.. I am not sure that I want to replace mine now. I was figuring on $40 to replace it, but for $100, it would be just as good to go back and unclog the one laying on my dock and reinstalling it. I was only gonna replace it because it was cheap.". Unbeknownst to me, there was a store manager standing at the next register behind me. He heard the whole conversation. He comes over, looks in the computer, and says, "I can do $4.50 a foot since you were quoted the wrong price before and putting a cut section of hose back on the shelf screws up our inventory. I can't do $3.99, though.". I thanked him, and left with my $45 hose. The 11' length should have been just shy of $110. My mood got a little better.

Step 4 through whatever - Got back to the dock with my new waste hose. Running it from the bildge to the head went very easy. I pulled it straight through and connected it to the head. I went into the midberth, made sure that the hose was running in as straight of a line as possible to the pass through to the engine compartment. It now has just a gentle slope upwards and towards the rear. If anything ever manages to clog up the hose again, I will be able to easily run a snake through it from the head side. Got into the bilge with a hack saw and diagonal wire cutters. Cut the hose to length and attached it to the tank inlet. Success!!! The head flushes marvelously once again. I was going to cut open the old hose to see what was clogging it, but I nixed that idea in favor of drinking the rest of the day away.

Stupid Vacuflush! :smt021
 
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Ski Bum

I feel your pain!
I had a few people on the boat over the weekend and a 6 year old on two weeks ago.
If I turn on the head system I hear the pump continue to run....occasionally will stop, but something for sure is wrong.
Looking up part numbers as I read posts.

Right now I have the admiral trained to turn it on and off as necessary...
But I know that will not be acceptable!!!

I am leaning towards taking an early day Friday and heading down to replace the duckbills.

Only good thing is, if there is any, is that my hoses and pump are so accessible it is a joke.
I can stand in the bilge with one hatch off and work at waist height to remove pump.
Thanks to the I/O's lots of room to work.

Pictures to follow.

Gary needs to chime in.....Duckbill Captain!!

Dan
 
What a great post! It seems the best tool in your toolbox is the one that "Irishes up" your coffee. I have a similar one - it works every time.
 
Sorry for your pain, but great story!

I had my first clog this weekend, too. Fortunately the, "put a stick in the ball and swish" cleared it first try... thank God I didn't have to go deeper...
 
Re: Vacuflush repair part 2...

Part 2, Day 2 - Maybe the duckbills are clogged?

Step 4 through whatever - Got back to the dock with my new waste hose. Running it from the bildge to the head went very easy. I pulled it straight through and connected it to the head. I went into the midberth, made sure that the hose was running in as straight of a line as possible to the pass through to the engine compartment. It now has just a gentle slope upwards and towards the rear. If anything ever manages to clog up the hose again, I will be able to easily run a snake through it from the head side. Got into the bilge with a hack saw and diagonal wire cutters. Cut the hose to length and attached it to the tank inlet. Success!!! The head flushes marvelously once again. I was going to cut open the old hose to see what was clogging it, but I nixed that idea in favor of drinking the rest of the day away.

Stupid Vacuflush! :smt021

1st rule of plumbing.....sh!t flows downhill!
 
Yeah, but that rule applies for plumbing that has vents, and uses gravity to create flow. This is a closed, powered system that renders the flowing down hill invalid. Given a a large enough pressure differential created by an overly complex, expensive piece of equipment, sh!t can be forced to flow uphill. :lol:

Seriously though, there isn't any way to get it back to the tank without going uphill. It has a 14" or so rise now. Sea Ray took it up 18-20" and then back down 4". Sealand's installation manual doesn't say anything about up or down, just about not making any tight radius turns... Hello... Sea Ray?... McFly?... Are you working for Sea Ray now?...
 
Having recently replaced my duckbills, and hose from the head to the tank, I can relate to what you just went through. I even had the friends sitting on the dock drinking beer and were thankful they weren't me. Now my friends think I'm the potty expert. Not a title I ever planned to earn.
 
Very entertaining post!! I had a couple of beers while reading it and almost felt like I was one of your buddies on the dock!!
Todd
 

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