Kohler HYDRO-TOWER 200 Series User manual

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HYDRO-TOWER 200
INSTALLATION INSTRUCTIONS
PNEUMATIC IN-WALL TANK
WITH FRAME (SHORT HEIGHT)
20007A-PNE-NA
20341T-PNE-CP
Read the installation guide carefully and install the product accordingly.
The product information contained in this publication is correct at the time of printing. Kohler Co. reserves the right to
implement changes to this guide, product characteristics, packaging and availability at any time without further notice.
Do not use corrosive cleaners or solvents in or on the tank. This may damage the tank. Mild detergent can be used.
Do not use any spare parts which are not supplied by Kohler. Kohler will not be responsible for any damage due to the
installation of non approved spare parts.
Observe all local plumbing and building codes. Installation shall be in accordance with AS/NZS 3500 and AS/NZS 6400.
HYDRO-TOWER 200 PNE IWT With Frame 3/4.5 ................................................................................................. 20007A-PNE-NA
PEBBLE Pneumatic In-Wall Tank Faceplate (For Separate Purchase) ...................................................................20341T-PNE-CP
1310920-A02-A
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 are listed on
the final page. Thanks again for choosing Kohler Company.
WARNING
BEFORE YOU BEGIN
This product is designed for a water supply pressure range of 20 psi (137kPa) minimum to 72.5psi (500 kPa) maximum.
Any installations where the supply pressure is outside of these limits will not be covered by warranty.
ORDERING INFORMATION
Liters per flush
Operating temperature
range
Environmental temperature:
Water temperature:
20007A-PNE-NA Full flush volume: 4.5L
Half flush volume: 3L
SPECIFICATIONS
RECOMMENDED TOOLS AND MATERIALS
10’’Adjustable
Wrench
Supply
Shut-off
Valve
Tape
Measure
Level Sponge Pipe wrench
Tubing Cutter Safety Glasses Drill and
assorted bits
Plus:
Connector
Metal File
1/2’’ Nut Driver/Socket
Saw
Screwdriver
M8 Coach/TEK Screws x 4
Apprpriate fasteners for masonary
or timber construction.

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UNIT:mm
20007A-PNE-NA installed with 20341T-PNE-CP Note: Set the final cistern height to achieve the required pan
height.
478
53
100
180
230
Ø90
438 150~185
Finished
floor
017
091~09
502
85~93
ROUGH-IN
013
Air hose
008detsegguSthgieH
The In-wall tank with frame (20007A-PNE-NA) should be used with wall hung toilets.
Note: Minimum cavity (stud pocket) dimensions for installation of the in-wall tank, 555mm wide, 170mm deep.
1. Remove the front cover or top cover from the tank as shown.
2. Remove the support block from inside of the tank.
3. Remove the plug.
In-Wall Tank With Frame
A1) INSTALLATION FOR IN-WALL TANK WITH FRAME
170mm MIN
555mm
Plug
Front
cover
Supporting
block
Top cover
Front
cover
Nog
20mm MIN

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To install on concrete:
1. Drill 4 holes with the diameter of Ø10
and 80mm depth.
2. Insert the flush head sleeve masonry
anchor and tighten the anchor bolts with
the nut by spanner.
3.Tighten the adjustable bracket by allen key.
Note: Ensure the tank is level.
4. Loosen the nut securing the adjustable bracket
and extend to the required height.Tighten the nut.
5. Fit the toilet fixing bolts in the required position
to suite the pan fixing holes (180mm or 230mm)
refer to toilet installation instruction. If no fixing
kit is supplied with the pan, use the fixing kit
supplied with the tank. Use lubricant as required
and ensureenough of the screw is exposed to
mount and secure the toilet.
6. Insert the frame screw and screw cap in the
holes of fixing frame, lock the frame screw with nut
on the base bracket.
7. Place the frame into the cavity.
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Allen bolt
Allen key
Adjustable bracket
Pan fixing
bolts
Nut
Tank frame
(4)
(5)
(6)
Base bracket
Frame screw
Screw cap
Gasket
Anchor bolt
Anchor bolt
To install on timber:
1. Place the frame into the cavity (stud pocket),
ensuring the front face of the frame is flush
with the front of stud.
2. Fix the adjustable brackets to the base plate
with coach/tek screws M8 (not supplied).
3. Place the nog (not supplied) on frame, ensuring
the bottom face of the nog is below the fixing hole
to provide enough area for a secure fixing.
4. Ensure the nog is level.
5. Mark the position of nog on both vertical studs.
6. Remove the nog.
7. Fix the nog to the studs.
8. Attach the frame to the nog. Use minimum M8
coach/tek screws (not supplied).
9. Tighten the screws.
10. Tighten the adjustable bracket by allen key.
Note: Ensure the tank is level.
P-trap installation
1. Loosen screw on waste pipe support bracket if required.
2. Insert the waste pipe connector.
3. Adjust waste connector position and tighten the waste pipe support bracket to secure the waste pipe connector.
Note: Ensure the flush pipe and waste pipe are the correct height from the finished floor level, refer to the toilet manufacturers
instructions and adjust if neccessary.
Coach Screw Base plate
Nog
Nog
Stud
Fixing Hole
M8 coach/tek
screw
A2) DISCHARGE OUTLET INSTALLATION METHODS

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4. Fit the waste pipe and the flush pipe covers.
S-trap installation
Connecting water inlet hose
1. Loosen the screw on waste pipe support
bracket if required.
2. Insert S-trap waste pipe into the waste pipe
support bracket.
3. Adjust the pipe position and tighten the
waste pipe support bracket screw to secure
the discharge elbow.
4. Insert the S-trap waste pipe lower end into
discharge port.
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Waste pipe
support bracket
Waste connector
Waste pipe cover
Flush pipe
cover
Tank frame
Bottom of the
S-trap waste pipe
Discharge port
Waste pipe
support bracket
S-trap
waste pipe
5. Fit the waste pipe and the flush pipe covers.
● Ensure the water tank internal shut off valve is OFF.
Note: Turn anti-clockwise to close and clockwise to open.
● Connect the water inlet hose (not supplied) to the tank
water inlet.
Flush pipe
S-trap waste pipe
Waste pipe cover
Tan kFrame
Flush pipe cover
Water inlet
hose
Tank water inlet

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A3) FACE PLATE/ACVESS PANEL INSTALLATION METHODS
There are four ways to install access panel:
Method one: Press from top
Method two: Remote locking plate installation
Method three: Remote installation of flush button shield
Method four:Press from front: fix four pinch plates with screws
Important: For methods two and three,remote access panel installation a removable panel must be installed either to the top or
front of the cistern access to the cistern parts/valves for maintenance purposes. Fix the cover onto the tank and pull the air hose
to the faceplate.
A3-1 :Press from top
Prepare and finish the wall
IMPORTANT:
a. When preparing the wall, the wallboard/tiling cut-out must fit very neatly
around the square cover of flush panel. No large gaps are permitted
(tolerance of approx 1mm).
b. There may be significant amounts of dust when preparing the wall - ensure
to fit dust cover over cistern opening and protect the electrical fittings and pipework.
c. We recommend before cutting the gib board the toilet is fitted to the frame to
verify the pan height is correct to the finished floor level. Cut the gib board to suit
the position of the flush plate, waste pipe, flush pipe and toilet fixing holes.
Fit the gib board to the stud.
3. Remove the waste pipe and flush pipe cover.
4. Using a sharp knife trim the flush plate sheild back level with the finished wall.
If the finished wall is to be tiled please ensure the thicknass of the tile is included.
The trimmed flush plate shield must sit flush with the finished wall.
5. Fix the locking plate to the flush plate shield using the plastic locking bolts.
When locating the four locking bolts on supporting board, turn the locking
bolts clockwise to the OPEN mark.
1. Remove the top cover, then install the rectangular shield on
the top of the tank, and tighten the screw to fix the shield.
2. Cut the cable tie of the air hose and pull it out from
the sheild.
Method one Method two Method three Method four
27~32
Air hose
Pinch
plate
Suggested faceplate
installation area
R1000mm
Air hose
Suggested faceplate
installation area
R1000mm Air hose
Pinch plate
Finished
wall
At least
80mm gap
required
Top cover
Screw
Shield
Cable tie
Front cover
Shield
waste pipe
cover
Flush pipe cover
Access panel
Access panel
Locking
plate
Locking
bolt

6. To lock the bolts in position turn the bolt counter-clockwise until the tab on the
bolt head is vertical to LOCK mark.
Note: Do not use excessive force - hand tighten only.
7. Trim the length of the locking bolts if required.
8. Fit the red full flush air hose and the blue reduced flush air hose to the faceplate.
9. Push the faceplate into the locking plate until it locks into place.
Note: Cut the excessive parts of the air hose if necessary and
fix it onto the tank fastener.
10. The cistern should now be ready to use.
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Fastener
Faceplate
Locking plate
Connect to blue
air hose (half flush)
Connect to red
air hose (full flush)
Full flush
Half
Flush
A3-2 :Remote locking plate installation
1. 7~20mm thickness is recommended for
the finished wall and at least 80mm gap
for faceplate.
2. Use four screws to fix locking plate by
four pinch plates to the wall.
3. Follow the steps 8-10 of A3-1 to complete the
faceplate installation.
A3-3 :Remote installation of flush button shield
1. Add a nog to studs where you want to install the faceplate to mo
A3-4 :Press from front: fix four plates with screws
1. Cut the cable tie of the air hose and pull it out from the tank
2. Ensure the tank is accessable through front or top for future maintenance.
3. Fix the four plates with screws and then fix the locking plate.
4. No direct contact between the faceplate and the tank as the 80mmgap is
required to support the faceplate thickness.
5. 7~20mm thickness recommended for the finished wall.
6. Follow the steps 8-10 of A3-1 to complete the faceplate installation.
unt the shield on.
2. Drill 4 holes with diameter of 10mm and depth
of 16mm are needed to locate the locking plate
bolts.
Drill 10mm hole for air hose on the side of sheild.
3. Mount the shield on nog using self-tapping screws.
4. Do not cut the shield as the full lenght of shield is
needed to accomodate the minimum space that is
required for faceplate.
5. Follow the steps 5-10 of A3-1 to complete the
faceplate installation.
At least 80mm
gap required
Air hose
Pinch plate
Finished
wall
Locking
plate
7~20mm
recommended
Air hose
Finished
wall
Fix sheild in wall
72
Screw
Pinch plates
Faceplate
Locking plate
Locking plate
Locking plate bolt
ø10 mm hole through hose
ø10 mm hole, depth
16mm locking bolt through
Space required
90
177
Position of locking
bolt through holes on nog
Nog
At least 80mm
gap reserved
Air hose
Pinch plate
Finished wall
Locking plate
7~20mm recommended

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48mm-58mm
Long screw
Lubricant
Level
Reserved space
6. Cut both the waste pipe and flush pipe at the connection distance marks.
7. Remove all burrs from the cut edges and reinstall on the toilet.
8. Fit the flush pipe connector and seal to the flush
pipe inlet on the toilet.
9. Fit the waste pipe connector and seal to the
waste pipe outlet on the toilet
10. Place the toilet onto the fixing bolts. (Ensure the toilet is supported at all times.)
11. Fit the rubber gasket, nut and decorative cap onto the fixing screws to secure
the toilet in place.
12. Ensure the toilet is level.
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1. Fit the flush pipe connector to the flush pipe inlet
on the toilet.
2. Fit the waste pipe connector to the waste pipe
outlet on the toilet.
3. Mark on the pipe connectors the position of
the rear of the toilet.
4. Remove the pipe connectors.
5. Mark on the pipe connectors a second line,
which represents the connection distance required
to connect the toilet to the flush and waste
pipes within the wall. This connection distance is
the distance between the rear of the tank and the
hole in the gib board.
Inlet pipe
Waste pipe
connector
A4) INSTALLATION OF TOILET
Mark showing position
of toilet rear
Connection distance
Waste pipe
connector
Inlet pipe
Inlet pipe Seal
Inlet pipe
Waste pipe
connector
Waste pipe
connector seal
Decorative cap
Gasket
Rubber cover
Nut
Screw cover
Toilet fixing bolt
1. First unlock the faceplate from the mounting frame.
2. Remove the full flush airhose and reduced flush airhose. Then remove the faceplate.
Faceplate
Faceplate
Connection
to air hose
B) REMOVAL AND MAINTEANCE OF CISTERN COMPONENTS

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3. Carefully loosen the four locking screws by rotating them clockwise until
the screw slots align with open tabs.
Warning: No tools or excessive force should be used to rotate the locking
screws to the ‘’OPEN’’ position.
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4. Disassemble faceplate supporting frame as shown. Locking plate
Locking bolt
6. Unscrew the hose from the inlet valve. Press the release
clip and lift to remove the inlet valve.
5. Rotate the shut off valve actuator handle clockwise to
open and anti-clockwise to close.
Valve
Close
Open
Quick release
connector
Nut
7. Push the clip of the toilet detergent box and lift to remove
from cistern.
8. Disconnect the oultet valve actuator arms for the full and
reduced flush by pushing towards the centre of the cistern
while applying pressure to both top and bottom of the pivot.
Remove the pneumatic actuator assembly by lifting the rear
of the frame to release the snap clips. Hold the pneumatic
hose ends and pull up to remove.
Clip
Lever snap
Snap (locked)

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9. To remove the flush valve Security tab at the
rear of the cistern, pull forward on the tab and lift out.
10.With the flush valve fastener removed, the flush valve can
be lifted out.
11. Remove discharge valve for cleaning or adjusting.
Cleaning the mesh filter
●To clean the mesh filter, release by rotating counter clockwise then pull free.
Rinse clean and fit before replacing the flush vavle.
Adjusting Inlet Valve
Adjusting Outlet Valve
● If the flush volume is incorrect, the flush volume and overflow
level of the tank can be altered by adjusting the valve:
For full flush, adjust the bottom slide adjustment switch. Adjust
up to increase volume.
For reduced flush adjustment, adjust the float level. Adjust up
to increase volume. The reduced flush water lower level will
be at the bottom of the float.
● Raise or lower the water level in the tank by adjusting the float
level with the adjusting screw. Turn clockwise to increase the
water level and counter clockwise to reduce. The water level
must align with the water line mark in the tank.
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Security tab
Outlet valve
Tighten
Close
Open
Corner
Open
A
Tighten
Close
C
Mesh filter
B
Outlet valve
Outlet valve
Control pole
Floating box
Adjusting screw
Spacer
Inlet valve
Adjustment switch
Floating box
Drainage valve

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TROUBLE SHOOTING PROCEDURES
No water fills in via inlet
valve
.evlavtelninepO.desolcsievlavtelniehT
Floating box of inlet valve is blocked by other parts.
Floating box of inlet valve is block by waste. Wash the floating box with clean water.
The air hose and faceplate are wrongly installed. Reinstall the air hose.
Not flushing
Too high or too low water
volume
Water leaking into toilet
pan
Toilet does not flush
Toilet does not flush
properly.
Symptoms Probable Causes Recommended Action
The actuator and flush vavle not connected. Reinstall the fastener bracket onto the body
of the outlet valve.
.
The floating box of the inlet valve is not properly
adjusted.
Readjust the water level to align with the
waterline mark.
The floating box of the inlet valve is blocked by
waste, so the water is leaking from the overflow
pipe.
A. No water supply.
B. The shut off valve is closed.
Readjust the position of other parts to avoid
contacting the floating box when it is
functioning.
A. Wait for restoration of water supply.
B. Open the water supply stop.
Readjust the position of other parts to avoid
contacting the floating box when it is
functioning.
The flush valve seal is blocked by waste or
damaged.
Filter screen is clogged.
Take out the outlet valve, clean, or replace
the rubber seal.
Clean the water mesh filter.
CONTACT & WARRANTY INFORMATION
For warranty information, please visit our website
Australia
www.kohler.com.au
New Zealand
www.kohler.co.nz
CALL US FOR HELP
NEW ZEALAND AUSTRALIA
KOHLER NZ LTD KOHLER CO.
Free Ph: RELHOK0081:hPeerF)RELHOK0080(7354650080
Free Fax: [phone] (1 800 564 537)
www.kohler.co.nz www.kohler.com.au