Sterling 404544-96 Installation guide

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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

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

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