8/3/2019 Korky Toilet Guts

1/1

Flush toilet and spongeremaining water fromtank.

Shut of f water supply.

Remove old flush valve & flapper.

Flush toilet several t imes. Periodically check for leaks forseveral days following installation. Call us with anycomments or questions.

Loosen locknut and extend upper tube toproper height. Hand-tighten locknut. Top offlush valve should be no more than 3/ 4"above water line marked in tank. Verify topof flush valve is at least 1" below bottom offlush lever nut.

Note: Verify C/ L line (critical level) on fillvalve or ballcock is at least 1" above top ofoverflow tube. This is a plumbing coderequirement.

Remove old tank-to-bowl sponge gasketand discard. Using alarge wrench removeand discardold flush valve,flapper &mounting nut.

Adjust height of flush valve.

Disconnect water supply line under tank.

Install new flush valve as shown.Don't forget to install flatchipboard washeragainst underside oftank. (This will reducefriction, making it easierto tighten plasticmounting nut by hand.)Hand-tighten mountingnut plus 1/4 turn max.(Do not over-tighten ortank may crack.)

Caution: If the top of theoverflow tube in your toilet ishigher than the flush leveropening, water could leak out.

Attach refill tube to fillvalve or ballcock and clipother end to overflow tubeas shown (S-shape hookprovided). Attach f lapperchain to lever. The chainshould have minimalslack.

Attach refill tube and flapper chain.

Connect water supply as shown.Pipe dope is not recommended.Hand-tighten only; do not over-tighten coupling nut.

Connect water supply line and t urn on water supply.

SS/ Braided connector shown

11.

7.

locknut

overflow tube

water line

overflow tube

locknut

1" min.

flush valve

flush lever nut

refill tubeflush lever

mounting nut

Vinyl/ SS Braided Connector

coupling nut

water supply valve

Flanged Metal Tubing

mounting nut

fiber washer

existing coupling nut

water supply valve

3/ 8" Flexible Copper Tubing

mounting nut cone washer

coupling nut

water supply valve

fiber washer

coupling nut

6.

8.

Check for leaks.

Lavelle Industr ies, Inc.665 McHenry StreetBurlington, WI 53105800-LAVELLEwww.korky.com

2005 Lavelle Industries, Inc.

GuaranteeThe Korky Flush Valve and Flapper aremade from engineered materials whichresist harsh chemicals and toilet tankcleaners. After proper installationaccording to these instructions; if it failswithin five years of purchase, return toLavelle. It will be replaced at no charge.

Future Troubleshooting Tips

Solution: Confirm that water supply valve is open all the way, and there are nokinks in supply line. If problem persists, replace fill valve or ballcock with KorkyQuietFill Valve, Lavelle model #528.

Problem: Toilet tank fills too slowly.

Problem: Fill valve or ballcock turns on and/or continuouslyruns, and water level rises above top of overflow tube ,spilling into overflow tube.

Problem: Fill valve or ballcock turns on and off by itself or runscontinuously (valve may hiss), but water level in tank remainsbelow top of oveflow tube.

Solution: Replace fill valve or ballcock with Korky QuietFill Valve, Lavellemodel #528.

Solution: Fill valve or ballcock is turning on or running due to a slowleak in the tank, most likely caused by a worn-out flapper. Replaceflapper with one of Lavelle's premium Korky toilet flappers for optimumperformance.

LIT078 Rev 7/ 05

Use either 2 or 3 bolt s as needed.(Do not over-tighten.) Push new spongegasket over flush valve threads andmounting nut.

chain flapper10.

Adjustable Flush Valve Kit (4030) Installation InstructionsTools requir ed:

spongebucketadjustablewrench or plierspipe wrenchruler ortape measurescrew driver

Save instructionsfor

future reference.

rubber washer brass washer brass hex nut sponge gasket

brass washer rubber washer

brass hex nut

mounting nut coupling nut

water supply line

FLUSH VALVE

FLAPPER

FILL VALVE

refill tube clip

water level

flush lever

brass bolt rubber seal

locknut

overflow tube

mounting nut

1.

2.

Remove nuts, washers & bolts. Discardold parts. Lift off tank from bowl.

Unbolt tank from bowl.3. 5.

SS/ Braided connector shown

Assemble bolts and washers to t ank as shown.

4.

9.

rubber washer

brass washer

brass hex nut

sponge gasket

brass bolt

mounting nut

sponge gasket

mounting nut

red rubber seal

brass washer rubber washer

brass hex nut

sponge gasket

tank floor

bowl

mounting nut chipboard washer

Ensure sponge gasket is properlypositioned on flush valve. Assemble asshown. Alternate hand t ightening ofnuts to ensure tankstays level. (Donot over-tighten.)

Reassemble tank to bowl.