Sterling 404544-96 Installation guide

Type
Installation guide
Tools and Materials
Thank You For Choosing Kohler Company
We appreciate your commitment to Kohler quality. Please take a few
minutes to review this manual before you start installation. If you
encounter any installation or performance problems, please don’t
hesitate to contact us. Our phone numbers and website are listed on
the back cover. Thanks again for choosing Kohler Company.
Before You Begin
WARNING: Risk of personal injury or water damage. Contents
of the vessel are under pressure and can cause severe injury. Do
not open or service before reading these installation instructions
or service instructions. Turn off the water supply and flush the
unit to release pressure before attempting any service.
WARNING: Risk of personal injury or product damage. Handle
with care. Vitreous china can break or chip if the bolts and nuts
are overtightened, or if the product is handled carelessly.
CAUTION: Risk of product damage. Do not use any oils or
lubricants on or in the pressure system.
Observe all local plumbing and building codes.
Carefully inspect the new toilet for damage.
If the existing toilet does not have a supply shut-off valve below
the tank, install one before installing the new toilet.
10" Adjustable
Wrench
Supply
Shut-Off
Valve
Tape
Measure
Tubing Cutter
Safety
Glasses
Sponge
Level
Putty Knife
Wax Seal
Plus:
• 5/16" T-Bolts with Nuts
and Washers
• Metal File
• Toilet Supply Tubing
• Hacksaw
• Screwdriver
1044956-2-B 2 Kohler Co.
1. Remove the Existing Toilet
CAUTION: Risk of hazardous gases. If the new toilet is not
installed immediately, temporarily place a rag in the closet
flange.
Turn off the water supply.
Flush the toilet.
Sponge out all remaining water from the tank.
Disconnect the supply shut-off valve, if present.
Remove the old toilet.
Remove the old wax seal from the floor with a putty knife.
Replace the old T-bolts with the new 5/16 diameter T-bolts.
T-Bolt
Scrape off the old
wax seal
Closet
Flange
Kohler Co. 3 1044956-2-B
2. Install the New Toilet
CAUTION: Risk of trap seal loss in back-to-back installations.
To prevent a trap seal loss, back-to-back toilet installations must
be connected to a vertical stack using one of the following three
fittings: double fixture, double combination wye and 1/8 bends,
or double wye and 1/8 bends.
CAUTION: Risk of external leakage. Do not lift or rock the
bowl after placement. If you break the watertight seal, you must
install a new wax seal.
CAUTION: Risk of product damage. Overtightening may cause
breakage or chipping of vitreous china.
Install or relocate the supply and outlet as necessary to conform
to the roughing-in dimensions.
Install a supply shut-off valve.
Record the model number in the Homeowners Guide.
Lay the toilet down onto a padded surface.
From the bottom of the toilet, firmly press a new wax seal around
the toilet outlet.
Remove the temporary rag (if used) from the toilet flange hole.
Align and lower the toilet over the flange and T-bolts.
Apply your full body weight around the toilet to set the seal.
Carefully tighten the nuts.
Bottom of Bowl
Wax Seal
Bolt Cap
Nut
Washer
Bolt Cap Base
T-Bolt
T-Bolt
Closet Flange
1044956-2-B 4 Kohler Co.
3. Install the Tank
CAUTION: Risk of product damage. Overtightening the tank
bolts may cause breakage or chipping of the vitreous china.
NOTE: Do not remove the pre-assembled tank bolts from the bottom
of the tank. The nuts and washers for securing the tank to the bowl
are packaged separately.
Verify that the factory installed rubber spacers are in place on the
tank bolts.
For Models K-3493 and K-3505 Only:
IMPORTANT! DO NOT remove the rubber spacers before
assembling the tank to the bowl.
For Model K-3554 Only:
IMPORTANT! To achieve a watertight seal, the rubber spacers must
be removed before assembling the tank to the bowl.
Remove the three rubber spacers from the tank bolts. Discard the
rubber spacers.
For All Models:
Position the tank on the bowl by centering the gasket on the bowl
inlet.
Assemble the washers and nuts to the tank bolts.
Tank Bolt
Gasket
Rubber
Spacer
Models K-3493 and K-3505
Remove
rubber
spacers.
Model K-3554 Only
Kohler Co. 5 1044956-2-B
Install the Tank (cont.)
IMPORTANT! For Models K-3493 and K-3505 Only: Tighten the
nuts until the rubber spacer makes contact with the top of the bowl
and the spacers begin to compress.
Tighten the nuts until they are snug. Do not overtighten the nuts.
Verify that the tank is level both left to right and front to back.
Make sure the nuts are tight enough to achieve a watertight seal.
1044956-2-B 6 Kohler Co.
4. Complete the Installation
Install the trip lever if one is not already installed. Follow the
instructions packed with the trip lever.
Connect the supply shut-off valve to the toilet supply shank.
Open the supply shut-off valve slowly to check for leaks. If the
connections have been properly assembled, a slight tightening of
the nuts should stop leakage.
Allow approximately one minute to bring the system to its
operating pressure.
Install the toilet seat according to the packed instructions.
Carefully set the cover onto the tank.
Flush and repressurize the toilet three times to stabilize the
system.
Flush the toilet several times and check all connections for leaks.
Periodically check for leaks for several days following the
installation.
Ferrule
Supply Shank
Tubing
Compression
Washer
Compression
Nut
Supply
Shut-Off
Valve
Supply Shut-Off Valve
Connection
Coupling
Nut
Fill Valve
Nut
Seal
Washer
Kohler Co. 7 1044956-2-B
5. Gap Clearance
NOTE: If the toilet does not activate, the gap between the actuator
and the plunger arm may need to be reset. Make sure the trip lever
handle is installed and the trip lever nut is tight. This is a left-hand
thread; turn the nut counterclockwise to tighten.
Make sure the water supply is on and the water from the supply
line has stopped flowing into the toilet.
Loosen the setscrew on the actuator. Do not fully remove the
setscrew.
Turn the actuator until there is a 1/16 (2 mm) - 1/8 (3 mm) gap
between the actuator and the plunger arm. Turn the actuator
clockwise to increase the gap.
Retighten the setscrew once the gap is properly adjusted.
IMPORTANT! Loss of gap clearance could cause leakage into the
toilet bowl. The plunger may not seal properly and may cause a
continual flow of water. If the problem is not corrected after
adjusting the actuator, refer to the troubleshooting section in the
Homeowners Guide.
Setscrew
Plunger Arm
Actuator
1/16" (2 mm) –
1/8" (3 mm) Gap
1044956-2-B 8 Kohler Co.
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Sterling 404544-96 Installation guide

Type
Installation guide

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