Kohler K-10668 Assembly instructions

Homeowners Guide
Exposed Flush Valve
Mproduct numbers are for Mexico (i.e. K-12345M)
Los números de productos seguidos de
Mcorresponden a México (Ej.
K-12345M)
Français, page “Français-1”
Español, página “Español-1”
K-10668
1140767-5-A

Table of Contents
EC Declaration of Conformity ............................. 3
Important Information ................................... 4
Your Kohler Electronic Valve .............................. 4
Control Stop Valve Operation ............................. 6
Remove the DC Sensor ................................. 7
Replace the Battery .................................... 8
Install the DC Sensor ................................... 9
Remove the Solenoid .................................. 10
Install the Solenoid .................................... 11
Clean/Replace the Diaphragm ........................... 12
Replace the Vacuum Breaker ............................ 14
Replace the Button Assembly ............................ 15
Warranty ........................................... 15
Troubleshooting ...................................... 17
Service Parts ........................................ 22
1140767-5-A 2 Kohler Co.

EC Declaration of Conformity
declare under our sole responsibility that our products, ELECTRONIC FLUSH VALVES, models:
We,
Kohler Company
444 Highland Drive, Kohler, WI 53044
Phone [phone]
EC DECLARATION OF CONFORMITY
K-10673
to which this declaration relates, are in conformity with the following standards:
Electromagnetic Compatibility Directive 89/336/EEC of 3 May 1989 as Amended by
92/31/EEC of 28 April 1992 and 93/68/EEC, Article 5 of 22 July 1993, based on:
• IEC 61000/ IEC 61000-3-:
"Electromagnetic Compatibility (EMC)";
Part 3: "Limits".
Section 2. "Limits for harmonic current emissions (equipment input current up to and including
16A per phase" (2000).
Section 3. "Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage
supply systems, for equipment with rated current <16 A per phase and not subjected to
conditional connection" (1995 + A1:2001).
• EN 61000-6-2/ EN 61000-6-2:
"Electromagnetic Compatibility (EMC) – Part 6-2: Generic standards – Immunity for industrial
environments" (2001).
• EN 55022 Class B:
"Information technology equipment – Radio disturbance characteristics – Limits and methods of
measurements" (1998 A1:2000 + A2:2003).
Low Voltage Directive 73/23/EEC of 19 February 1973 as Amended by 93/68/EEC, Article 13 of
22 July 1993, based on:
• EN 60730/1:
"Specification for Automatic Electrical Controls for Household and Similar Use. General
Requirements".
• EN 60730/2/8:
"Specification for Automatic Electrical Controls for Household and Similar Use. Particular
Requirements for Electrically Operated Water Valves, Including Mechanical Requirements".
Timothy J. Stessman
Codes & Standards Dept.
Kohler Company
November 18, 2008
DateSignature
November 18, 2008 08
K-10677
K-10674
K-10678
K-10675
K-10679
K-10676 K-10668
K-10666
Kohler Co. 3 1140767-5-A

Important Information
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
This device may not cause harmful interference.
This device must accept any interference received, including
interference that may cause undesired operation.
NOTE: This equipment has been tested and found to comply with
the limits for a Class B digital device, pursuant to Part 15 of the
FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation.
This equipment generates, uses and can radiate radio frequency
energy and, if not installed and used in accordance with the
instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference
will not occur in a particular installation.
If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and
on, the user is encouraged to try to correct the interference by one or
more of the following measures.
•Reorient or relocate the receiving antenna.
•Increase the separation between the equipment and receiver.
•Connect the equipment into an outlet on a circuit different from
that to which the receiver is connected.
•Consult the dealer or an experienced radio/television technician
for help.
Modifications: Any modifications made to this device that are not
approved by Kohler Co. may void the authority granted to the user by
the FCC to operate this equipment.
This Class B digital apparatus complies with Canadian ICES-003.
Your Kohler Electronic Valve
Design Features
The valve is designed specifically for use with 1-1/2″(1.9 cm) top spud
toilets as offered by Kohler Company and others.
The valve is supplied with factory preset timing values. No
programming or adjustment is required.
1140767-5-A 4 Kohler Co.

Your Kohler Electronic Valve (cont.)
Depending upon use,a9Vlithium battery can be expected to last for
two to three years before replacement is required.
Flush Operations
The exposed electronic valve provides the following flushing
operations:
Wave activated main flush operation: Shortly after the individual
departs the fixture, the valve provides a main flush that lasts for
several seconds.
Automatic 24-hour flush operation: After 24-hours of non-use,
the valve produces a full flush.
Low Battery Indication
The 9 V lithium battery can be expected to last for two to three years
before replacement is required. When the battery reaches a certain
point in its lifetime, the valve announces the low battery condition by
continuously flashing an LED whenever a user is in range. The battery
is easily replaced as described in the section ″Replace the Battery″in
this guide.
Replacement batteries can be purchased from drugstores or other stores
stocking batteries. The required battery is a standard 9 V lithium.
Seasonal Use
The exposed electronic valve is not designed for operation in freezing
conditions. If freezing conditions are expected, isolate and drain the
valve along with whatever other winterization steps are taken for the
facility.
Mobile Use
The exposed electronic valve is not designed for use in moving
environments such as boats.
Kohler Co. 5 1140767-5-A

Control Stop Valve Operation
Use a strap wrench to remove the vandal-resistant cap from the
control stop valve.
Close the stop valve by turning the valve screw clockwise as far
as it can go.
Open the stop valve by turning the valve screw counterclockwise
as far as it can go.
When done, place the stop cap on the control stop valve and
tighten using a strap wrench.
Wall Flange
Wall Tube
Control Stop
Stop Cap
1140767-5-A 6 Kohler Co.

Remove the DC Sensor
Close the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Using a 3/32″hex head wrench, remove the setscrew from the
valve cap.
Remove the cap by carefully lifting from the valve body.
Disconnect the DC sensor connector to the solenoid by grasping
each side of the connector pair and pulling apart. Do not separate
the connector pair by pulling on the wires.
Position the cap on its side and look inside.
Remove the battery.
Remove the screws that hold the DC sensor in place inside the
cap.
Turn the cap over and slide the DC sensor, sensor strap, and
screws into your hand.
NOTE: The battery inside the sensor may be considered hazardous
waste. Discard the old DC sensor and/or battery in accordance with
any applicable codes.
If replacing the DC sensor, discard the old DC sensor and battery.
Cap
Setscrew
DC Sensor
DC Sensor
Connector
Sensor Strap
Screw
Kohler Co. 7 1140767-5-A

Replace the Battery
NOTE: When purchasing a replacement battery, selecta9Vlithium
battery.
NOTE: If replacing the sensor, install a battery in the new sensor
unit before installing the sensor.
NOTE: It is not necessary to remove the sensor from the cap to
replace the battery.
Using a 3/32″hex wrench, remove the setscrew from the cap.
Remove the cap.
Using a small, flat-blade screwdriver (if necessary), carefully pry
the battery from the cap.
Disconnect the battery and remove the battery boot.
NOTE: The battery may be considered hazardous waste. Discard the
old battery in accordance with any applicable codes.
Discard the old battery.
Connect the new battery. Install the battery boot over the
connections.
Reinstall the battery into the cap.
Reinstall the cap.
Battery
Setscrew
Battery Boot
Cap
1140767-5-A 8 Kohler Co.

Install the DC Sensor
NOTICE: Do not pinch or kink the wires between the cap and the
valve body. If the wires are damaged, the unit may not operate.
Hold the cap vertically with the sensing holes down and align the
DC sensor with the cap.
Slide the DC sensor into the cap until the sensor eye aligns with
the hole in the cap. Ensure the sensor wires are not pinched.
Place the sensor strap over the DC sensor and tighten the screws
in the cap until snug.
Connect the DC sensor connector to the solenoid connector on the
valve. Ensure that the connector pair is fully seated.
Locate the connector assembly adjacent to the battery to prevent
pinching when the cap is reinstalled on the valve.
Place the cap on the valve body.
Secure the cap with the setscrew.
Open the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Reinstall the stop cap onto the control stop and tighten firmly
with a strap wrench.
Verify that the valve functions.
Cap
Setscrew
DC Sensor
DC Sensor
Connector
Sensor Strap
Screw
Kohler Co. 9 1140767-5-A

Remove the Solenoid
Close the control stop valve (refer to the ″Control Stop Valve
Operation″section).
NOTE: If the unit has not flushed since the stop valve was closed,
the inlet arm may still be pressurized. Use the manual flush button
to release pressure.
Use a 3/32″hex wrench to remove the setscrew from the cap.
Remove the cap.
Disconnect the DC sensor connector from the solenoid connector
by pulling the two connectors apart.
Temporarily store the cap and DC sensor assembly in a safe
place.
Use an adjustable wrench to remove the solenoid assembly from
the valve body by unscrewing counterclockwise until the solenoid
is free.
Valve Body
Diaphragm
Cap
Setscrew
O-Ring
Piston
Retaining Nut
Pin
Spring
Piston Cover
Solenoid
Connector
DC Sensor
Connector
Solenoid
Assembly
1140767-5-A 10 Kohler Co.

Install the Solenoid
NOTICE: Do not overtighten the solenoid, as damage to the
solenoid can occur.
NOTICE: Do not pinch or kink the wires between the cap and the
valve body. If the wires are damaged, the unit may not operate.
Align the solenoid with the hole in the piston cover.
Install the solenoid and tighten with an adjustable wrench by
turning clockwise.
Connect the DC sensor connector to the solenoid connector and
locate the connector assembly next to the sensor body to avoid
pinching.
Place the cap on the valve body and secure with the setscrew.
Open the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Verify that the valve functions.
Valve Body
Diaphragm
Cap
Setscrew
O-Ring
Piston
Retaining Nut
Pin
Spring
Piston Cover
Solenoid
Connector
DC Sensor
Connector
Solenoid
Assembly
Kohler Co. 11 1140767-5-A

Clean/Replace the Diaphragm
NOTICE: Do not pinch or kink the wires between the cap and the
valve body. If the wires are damaged, the unit may not operate.
Close the control stop valve (refer to the ″Control Stop Valve
Operation″section).
NOTE: If the unit has not flushed since the stop valve was closed,
the inlet arm may still be pressurized. Use the manual flush button
to release pressure.
Use a 3/32″hex wrench to remove the setscrew from the cap.
Remove the cap from the valve body.
Disconnect the DC sensor connector from the solenoid connector
by pulling the connectors apart.
Temporarily store the cap and DC sensor in a safe place.
Use an adjustable wrench to remove the solenoid.
Remove the diaphragm.
NOTE: Take care not to lose the spring and pin contained within the
solenoid assembly.
Rinse any debris from the diaphragm.
Verify the spring and pin are still in place in the solenoid
assembly.
If replacing, insert a new diaphragm onto the solenoid assembly.
Valve Body
Diaphragm
Cap
Setscrew
O-Ring
Piston
Retaining Nut
Pin
Spring
Piston Cover
Solenoid
Connector
DC Sensor
Connector
Solenoid
Assembly
1140767-5-A 12 Kohler Co.

Clean/Replace the Diaphragm (cont.)
Thread the solenoid into the piston cover and tighten with an
adjustable wrench.
Verify the piston remains in place.
Install the solenoid/cover assembly into the valve body.
Connect the DC sensor connector to the solenoid connector.
Place the cap on the valve body and install the two screws.
Open the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Verify that the valve functions.
Kohler Co. 13 1140767-5-A

Replace the Vacuum Breaker
Close the control stop valve (refer to the ″Control Stop Valve
Operation″section).
NOTE: If the unit has not flushed since the stop valve was closed,
the inlet arm may still be pressurized. Use the manual flush button
to release pressure.
Use a large adjustable wrench to loosen the large tube nut at the
base of the valve body. Let the tube nut slide down the tailpiece.
Gently rotate the top of the valve body away from you while
pulling the top of the tailpiece toward you to separate the
tailpiece from the valve body. The vacuum breaker should now
be exposed for removal.
Remove the loose fiber washer and vacuum breaker from the
tailpiece. Discard both the fiber washer and vacuum breaker.
Install a new vacuum breaker into the tailpiece and place a new
fiber washer on the top of the vacuum breaker.
Gently rotate the tailpiece and valve body back together until the
large tube nut can be threaded onto the bottom of the valve body.
Tighten the large tube nut with a large adjustable wrench.
Open the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Verify that the valve functions.
Tailpiece
Valve Body
Escutcheon
Coupling Nut
Rubber Seal
Fiber Washer
Large Tube Nut Inlet Arm Nut
Fiber
Washer
Control
Stop
Vacuum
Breaker
1140767-5-A 14 Kohler Co.

Replace the Button Assembly
Close the control stop valve (refer to the ″Control Stop Valve
Operation″section).
NOTE: If the unit has not flushed since the stop valve was closed,
the inlet arm may still be pressurized. Use the manual flush button
to release pressure.
Carefully place a properly sized spanner wrench or a pair of
needle-nose pliers into the holes on the end of the flush button.
Remove the flush button assembly from the valve body.
NOTE: The flush button can only be serviced as a complete
assembly. There are no serviceable internal parts.
Carefully thread a new flush button assembly into the valve body.
Tighten with a spanner wrench or needle nose pliers.
Open the control stop valve (refer to the ″Control Stop Valve
Operation″section).
Verify that the valve functions.
Warranty
KOHLER
®
Electronic Faucets, Valves and Controls
FIVE-YEAR LIMITED WARRANTY
Kohler Co. warrants that its electronic faucets, valves and controls will
be free of defects in material and workmanship during normal
Holes
Valve Body
Flush Button
Assembly
Kohler Co. 15 1140767-5-A

Warranty (cont.)
residential use for five years from the date the product is installed.
This warranty applies only to electronic faucets, valves and controls
installed in the United States of America, Canada and Mexico (″North
America″).
If a defect is found in normal residential use, Kohler Co. will, at its
election, repair, provide a replacement part or product, or make
appropriate adjustment where Kohler Co.’s inspection discloses any
such defect. Damage caused by accident, misuse, or abuse is not
covered by this warranty. Improper care and cleaning will void the
warranty*. Proof of purchase (original sales receipt) must be provided
to Kohler Co. with all warranty claims. Kohler Co. is not responsible
for labor charges, installation, or other incidental or consequential costs
other than those noted above. In no event shall the liability of Kohler
Co. exceed the purchase price of the faucet, valve or control.
If the electronic faucets, valves or controls are used commercially or are
installed outside of North America, Kohler Co. warrants that the
faucet, valve or control will be free from defects in material and
workmanship for one (1) year from the date the product is installed,
with all other terms of this warranty applying except duration.
If you believe that you have a warranty claim, contact your Home
Center, Dealer, Plumbing Contractor or E-tailer. Please be sure to
provide all pertinent information regarding your claim, including a
complete description of the problem, the product, model number, the
date the product was purchased, from whom the product was
purchased and the installation date. Also include your original invoice.
For other information, or to obtain the name and address of the service
and repair facility nearest you, write Kohler Co., Attn: Customer Care
Center, Kohler, Wisconsin 53044 USA, or by calling 1-800-4-KOHLER
(1-800-456-4537) from within the USA and Canada, and
001-800-456-4537 from within Mexico, or visit www.kohler.com within
the USA, www.ca.kohler.com from within Canada, or
www.mx.kohler.com in Mexico.
THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
KOHLER CO. AND/OR SELLER DISCLAIM ANY LIABILITY FOR
SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES. Some
states/provinces do not allow limitations on how long an implied
warranty lasts or the exclusion or limitation of such damages, so
these limitations and exclusions may not apply to you. This warranty
1140767-5-A 16 Kohler Co.

Warranty (cont.)
gives the consumer specific legal rights. You may also have other
rights that vary from state/province to state/province. This warranty
is to the original consumer purchaser only, and excludes product
damage due to installation error, product abuse, or product misuse,
whether performed by a contractor, service company, or the
consumer.
This is Kohler Co.’s exclusive written warranty.
*Never use cleaners containing abrasive cleansers, ammonia, bleach,
acids, waxes, alcohol, solvents or other products not recommended
for chrome. This will void the warranty.
Troubleshooting
This troubleshooting guide is for general aid only. The steps are
recommended rather than required. This guide should provide an
indication of the probable fault and a suggested correction. For
warranty service, contact your dealer or wholesale distributor.
•For replacement parts, call the Kohler Customer Care Center at
1-800-4-KOHLER from 7 AM to 6 PM Central Standard Time or
order online 24 hours at www.kohler.com.
•All work should be performed by properly qualified or licensed
personnel as required by local codes.
Kohler Co. 17 1140767-5-A

Troubleshooting (cont.)
Symptom Probable
Cause Recommended Action
1. No flow. A. Water is
not turned
on.
•Verify that the water supply is
turned on and that water
pressure is at a minimum of 35
psi (2.4 bars).
•Verify that the control stop is
fully in the open position.
B. Loose
connection.
•Remove the valve cover.
•Check the connection from the
sensor to the solenoid.
C. Wires are
pinched or
damaged.
•Remove the valve cover.
•Inspect the wires for cuts or
damage.
•If required, order a new
solenoid or a new sensor
assembly.
•Verify that both wires are
tucked inside the cover before
reassembling.
D. Battery life
has
expired.
•NOTE: The unit requires one 9
volt lithium battery. This item
is not available from Kohler
but can be purchased at
convenience stores.
•Follow the directions of
″Replace the Batteries″section
in this guide.
E. Solenoid
does not
work.
•Order a new solenoid service
kit.
F. Sensor
eyes are
scratched.
•Replace the sensor assembly.
Follow the directions of
″Remove the DC Sensor″and
″Install the DC Sensor″sections
in this guide.
G. Bleed hole
in the
diaphragm
is plugged
or debris is
on seal.
•Follow the directions of
″Clean/Replace the
Diaphragm″section in this
guide.
•NOTE: Take care to replace the
diaphragm in its seat before
installing it into the valve body.
1140767-5-A 18 Kohler Co.

Troubleshooting (cont.)
Symptom Probable
Cause Recommended Action
2. Low flow. A. Supply
stop is not
fully open.
•Remove the cover on the end
of the supply stop.
•Turn the supply stop screw
counterclockwise until it is in
the fully open position.
•Replace the cover.
B. Supply
stop is not
allowing
enough
flow.
•Remove the cover on end of
the supply stop.
•While testing the flush, adjust
the supply stop screw
counterclockwise until
adequate flow is achieved.
•Replace the cover.
C. Supply
pressure is
low.
•Check any filtration systems for
blockage.
•Measure the incoming water
pressure. Minimum pressure
should be 35 psi (2.4 bar).
3. Constant
flow. A. Filter is plugged.
•Follow the directions of ″Clean
the Screen/Replace the Piston″
section in this guide.
B. Diaphragm
seal is
dirty or
damaged.
•Follow the directions of
″Clean/Replace the
Diaphragm″section in this
guide.
•NOTE: Take care to replace the
diaphragm in its seat before
installing it into the valve body.
•If the diaphragm is cut or torn,
order a new diaphragm
assembly.
C. Solenoid is
not
working.
•Order and install a new
solenoid assembly.
•Follow the directions of
″Remove the Solenoid″and
″Install the Solenoid″sections
in this guide.
Kohler Co. 19 1140767-5-A

Troubleshooting (cont.)
Symptom Probable
Cause Recommended Action
4. Sporadic
flow. A. Wires are pinched or
damaged.
•Remove the valve cover.
•If wires are cut or damaged,
order new solenoid or sensor
assembly.
•Verify that both wires are
tucked inside the cover before
reassembling.
B. Low
battery.
•Follow the directions of
″Replace the Battery″section in
this guide.
5. Water is
leaking
from the
vacuum
breaker
connection
with the
valve.
A. Vacuum
breaker is
worn, or
damaged.
•Turn off the water supply.
•Purge the valve.
•Disconnect the valve from the
vacuum breaker assembly.
•Replace rubber vacuum
breaker.
•Reassemble the valve to the
vacuum breaker assembly.
6. Water
leaking
from the
valve inlet.
A. Arm to
control
stop seal is
worn or
damaged.
•Turn off the water supply.
•Purge the valve.
•Disconnect the valve from the
control stop.
•Inspect the O-ring seal for the
control stop to inlet connection.
•Clean any debris from area.
•If the O-ring is cut or torn,
order a replacement.
•Reassemble the unit, taking
care to tighten the nut onto the
control stop.
1140767-5-A 20 Kohler Co.