KOHLER K-1106, K-1112, K-1114, K-1126, K-1131 User Manual

...

Installation Guide

Flanged 120 V Bath Whirlpool

K-1106, K-1112, K-1114, K-1126, K-1131, K-1139, K-1144, K-1154, K-1157, K-1160, K-1192, K-1194, K-1196, K-1198, K-1209,

K-1224, K-1239, K-1244, K-1257, K-1266, K-1458,

K-1630, K-1635

M product numbers are for Mexico (i.e. K-12345M) Los números de productos seguidos de M corresponden a México (e.j. K-12345M) Français, page “Français-1” Español, pagina “Español-1”

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Important Information

WARNING: When using electrical products, basic precautions should always be followed, including the following:

DANGER: Risk of electric shock. Connect only to a circuit protected by a Ground-Fault

Circuit-Interrupter (GFCI).

Building materials and wiring should be routed away from the pump body and other heat-producing components of the unit.

Install to permit access for servicing.

Grounding is required. The unit should be installed by a qualiﬁed service representative, and grounded.

WARNING: Risk of electric shock. A licensed electrician should make all electrical connections.

WARNING: Risk of electric shock. Disconnect power before servicing.

WARNING: Risk of injury or property damage. Please read all instructions thoroughly before

beginning installation, including the following requirements.

NOTICE: Follow all local plumbing and electrical codes.

Product Information

Electrical Requirements

The installation must have a Class A Ground-Fault Circuit-Interrupter (GFCI). The GFCI protects against line-to-ground shock hazard. Use a 120 V, 15 A, 60 Hz dedicated service for the whirlpool.

″H″ models require a separate 120 V, 15 A, 60 Hz dedicated service for the heater.

NOTE: If the pump supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualiﬁed persons in order to avoid a hazard. The heater supply cord cannot be replaced. If the cord is damaged the heater should be scrapped.

Product Notices

WARNING: Unauthorized modiﬁcation may cause unsafe operation and poor performance of the whirlpool. Do not relocate the whirlpool pump, or make other modiﬁcations to the whirlpool system,

as this could adversely affect the performance and safe operation of the whirlpool. Kohler Co. shall not be liable under its warranty or otherwise for personal injury or damage caused by any such unauthorized modiﬁcation.

Factory-Assembled Features

Factory installed components include pump with power supply cord and air switch transmitter. No installation is needed.

″H″ models are also supplied with a factory assembled heater. An optional timer kit is available for this certain models. The whirlpool pump and piping are factory-assembled.

Connections and Service Access

Before installation, ensure proper access to the ﬁnal connections.

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Important Information (cont.)

NOTICE: Provide unrestricted service access to the pump. You must provide access for servicing the pump and controls. The access must be located immediately next to the pump. Study the roughing-in information packed with the whirlpool.

Table of Contents

Important Information .............................................................. 2

Thank You For Choosing Kohler Company .............................................. 4

Tools and Materials ............................................................... 4

Before You Begin ................................................................. 5

Prepare the Site ................................................................. 6

Prepare the Whirlpool ............................................................. 6

Secure the Whirlpool — Models With Support Blocks ...................................... 7

Secure the Whirlpool — Models With Whirlpool Base ...................................... 8

Secure the Whirlpool to the Stud Framing ............................................... 9

Cut the Pump Banding Straps ....................................................... 9

Install the Plumbing ............................................................... 9

Make Electrical Connections ........................................................ 10

Test Run the Whirlpool ............................................................ 11

Complete the Finished Wall ........................................................ 12

Removing the Apron .............................................................. 12

Clean-Up After Installation ......................................................... 12

Conﬁrm Proper Operation .......................................................... 13

Troubleshooting Procedure ......................................................... 14

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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 your 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.

Tools and Materials

Plus:

• Conventional woodworking tools

Sealant

Safety Glasses

Tape Measure

Pipe Wrench

Pencil

Level

and materials

• Drop Cloth

• Construction adhesive (optional)

• Cement or mortar (optional)

• 2x4's or 2x6's

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Install the outlets for the pump and heater (if used) to the mounting plate.

Outlet

Before You Begin

CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the piping or pump for structural support of the whirlpool.

We recommend this whirlpool for alcove or corner installation. Inspect the whirlpool for damage before you begin installation. You must install this whirlpool to an adequately supported, level subﬂoor. Conﬁrm adequate mounting and connection space for the faucet speciﬁed for your installation. For corner units with integral apron: Have a qualiﬁed electrician install the outlets for the pump

and heater (if used) at the speciﬁed location on the whirlpool. Refer to the above illustration.

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Position the rough plumbing.

Construct 2x4 or 2x6 stud framing according to the roughing-in information.

Verify that the subfloor offers adequate support, and is flat and level.

Position the rough plumbing.

Construct 2x4 or 2x6 stud framing according to the roughing-in information.

Provide a 1/16" (2 mm) gap between the whirlpool rim and framing.

Frame the floor according to the roughing-in information.

Verify that the subfloor offers adequate support, and is flat and level.

1. Prepare the Site

NOTICE: Unless otherwise speciﬁed, ﬂoor support under the whirlpool must provide for a minimum of 80 lbs./square foot (390 kg/square meter) loading.

NOTICE: Do not support the whirlpool by the rim.

Make sure the ﬂooring offers adequate support for your whirlpool, and verify that the subﬂoor is ﬂat and level.

For Whirlpools without Apron:

The whirlpool should be installed in a drop-in installation. Construct 2x4 or 2x6 stud framing designed for your particular installation. Provide for a 1/16″ (2 mm) gap between the bottom of the whirlpool rim and the stud framing. Frame the ﬂoor, or construct a frame for a raised installation in accordance with the roughing-in information packed with the whirlpool.

Carefully lay out and cut the rough deck material. Use the cut-out template if one is provided, or refer to the roughing-in cut-out information.

For Whirlpools with Integral or Optional Apron:

The whirlpool should be installed in an alcove or corner installation, depending upon the model chosen. Construct 2x4 or 2x6 stud framing designed for your particular installation. Construct a frame in accordance with the roughing-in information packed with the whirlpool.

For All Installations:

Position the plumbing according to the roughing-in information packed. Cap the supplies, and check for leaks.

2. Prepare the Whirlpool

Install the drain to the whirlpool according to the drain manufacturer’s instructions. Do not connect the trap at this time.

Position a clean drop cloth or similar material in the bottom of the whirlpool. Be careful not to scratch the surface of the whirlpool.

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Spread a 2" (5.1 cm) layer of cement or mortar bed material.

Apply construction adhesive to the support blocks.

Clear space for pump.

Clear spaces for support blocks.

3. Secure the Whirlpool — Models With Support Blocks

CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the piping or pump for structural support of the whirlpool.

CAUTION: Risk of product damage. Do not support the whirlpool by the rim.

Choose the installation option that best applies to your particular installation. Follow the appropriate instructions.

If the subﬂoor is not level, shim the whirlpool support blocks as necessary.

Option Using a Cement or Mortar Bed

NOTE: Do not use gypsum cement or drywall compound for this application, as they will not provide an acceptable, durable bond.

NOTE: The pump support bracket (when the pump banding straps are cut) and support blocks must rest directly on the subﬂoor.

Spread a 2″ (5.1 cm) thick layer of cement or mortar on the subﬂoor where the whirlpool will be set. This will help secure, level, and support the unit. Clear all the material away from the pump support bracket and support block locations.

Position a piece of plastic drop cloth material on top of the cement or mortar bed. With help, carefully lift the whirlpool into place, and make sure the pump support bracket and support blocks do not rest in the bed material.

Insert the drain tailpiece into the trap. Make sure the whirlpool is level and resting on all support blocks.

Option Using Construction Adhesive

Apply a generous amount of high-quality construction adhesive to the bottom of the support blocks. With help, carefully lift the whirlpool into position.

Insert the drain tailpiece into the trap. Make sure the whirlpool is level and resting on all support blocks.

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Spread a 2" (5.1 cm) layer of cement or mortar bed material.

Apply construction adhesive to the whirlpool base.

4. Secure the Whirlpool — Models With Whirlpool Base

CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the piping or pump for structural support of the whirlpool.

CAUTION: Risk of product damage. Do not support the whirlpool by the rim.

Choose the installation option that best applies to your particular installation. Follow the appropriate instructions.

If the subﬂoor is not level, shim the whirlpool base as necessary.

Option Using a Cement or Mortar Bed

NOTE: Do not use gypsum cement or drywall compound for this application, as they will not provide an acceptable, durable bond.

Spread a 2″ (5.1 cm) thick layer of cement or mortar on the subﬂoor where the whirlpool will be set. This will help secure, level, and support the unit.

Position a piece of plastic drop cloth material on top of the cement or mortar bed. With help, carefully lift the whirlpool into place.

Insert the drain tailpiece into the trap. Make sure the whirlpool is level. Use screws or lag bolts to secure the whirlpool base to the ﬂoor. Drill small pilot holes through the whirlpool base as needed.

Option Using Construction Adhesive

Apply a generous amount of high-quality construction adhesive to the bottom of the whirlpool base. With help, carefully lift the whirlpool into position.

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Nail 1/4" (6 mm) thick furring strips to the studs.

Stud

Use #6 large-head galvanized nails to secure the nailing-in flange to the studs.

Drill a small hole through the nailing-in flange at each stud.

Drainage

NOTE:

Pump

Cut the pump banding straps.

Suction Line

Pump model illustrated may differ from your actual product.

5. Secure the Whirlpool to the Stud Framing

Drill a small pilot hole through the nailing-in ﬂange at each stud. Add shims between the nailing-in ﬂange and the studs as needed to eliminate gaps.

Nail 1/4″ (6 mm) thick furring strips to the studs to shim out to the edge of the nailing-in ﬂange. Use #6 large-head galvanized nails to secure the nailing-in ﬂange to the studs.

6. Cut the Pump Banding Straps

IMPORTANT! This step is necessary to make your Kohler whirlpool operate more quietly.

NOTE: Do not raise the pump higher than it was before you cut the pump banding straps. If the pump is

raised too high, it will not prime properly.

Use tin snips to cut the two pump banding straps. When the banding straps are cut, the pump support bracket and pump will drop about 1/2″ (1.3 cm) until they rest on the subﬂoor. If the pump drops more than 1/2″ (1.3 cm), shim under the pump support bracket so there is a 1/2″ (1.3 cm) gap between the pump and bracket to allow for proper drainage.

To minimize whirlpool noise and vibration, be sure the pump is not in direct contact with the shipping bracket after the pump banding straps are cut.

Secure the pump support bracket to the subﬂoor with screws or lag bolts (not provided).

7. Install the Plumbing

CAUTION: Risk of property damage. Ensure a watertight seal on the whirlpool drain.

Connect the drain to the trap according to the drain manufacturer’s instructions. Install the faucet valving according to the faucet manufacturer’s instructions. Do not install the

faucet trim until instructed. Open the hot and cold water supplies, and check the supply connections for leakage.

Run water into the whirlpool, and check the drain connections for leakage.

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Install a GFCI-protected 120 V, 15 A grounded outlet. Install a second GFCI-protected outlet for "H" models for the heater.

Optional heater (models may vary) either T-style (shown) or water intake (not shown)

Make sure the air actuator tubing is securely attached to the pump.

Plug pump and

Bond in accordance with applicable codes.

NOTE:

Pump model illustrated may differ from your actual product.

heater into these outlets.

8. Make Electrical Connections

WARNING: Risk of electric shock. To reduce the risk of electrical shock, connect the pump and in-line heater (if heater option included) to properly grounded, grounding-type receptacles protected by Ground-Fault Circuit-Interrupters (GFCI’s). Do not remove the plugs’ grounding pins. Do not use grounding adapters.

Pump Wiring

NOTE: The whirlpool model number is printed on a label near the whirlpool pump. This label also identiﬁes the electrical rating of the whirlpool.

Your Kohler whirlpool bath is equipped with a cord and plug. All wiring of the pump and control has been completed at the factory. A licensed electrician must install a GFCI-protected, 120 V, 15 A, grounded outlet. No other load should be on this circuit. Locate the outlet behind the whirlpool, and within 24″ (61 cm) of the pump.

Plug the pump into this outlet.

NOTE: Make sure the air actuator tubing is securely attached to the pump, and is not kinked or damaged.

If a K-1639 Timer Kit will be used, install it now according to the instructions packed.

In-Line Heater Wiring

″H″ Models: The heater is equipped with a cord and plug. All wiring of the heater has been completed at the factory. A licensed electrician must install a GFCI-protected, 120 V, 15 A, grounded outlet. No other load should be on this circuit. Locate the outlet behind the whirlpool, and within 24″ (61 cm) of the heater.

Plug the heater into this outlet.

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Turn the jet trim ring clockwise to decrease the flow.

Fill with water 2" (5.1 cm) above the highest jet.

Position the jet nozzles to direct the water flow as desired.

Turn the jet trim ring counterclockwise to increase the flow.

Press the air actuator to turn on and off the whirlpool.

9. Test Run the Whirlpool

Check all electrical connections, and make sure the electrical power to the whirlpool and heater (if equipped) is on.

Make sure all union connections to the pump and heater are securely hand tightened. Verify that the pump banding straps have been cut (if applicable), and that the pump is resting

directly on the subﬂoor or whirlpool base. Fill the whirlpool to a level at least 2″ (5.1 cm) above the top of the highest jet. Operate the whirlpool for 5 minutes, and check all whirlpool piping connections for leaks. For additional information on whirlpool operation, refer to ″Conﬁrm Proper Operation″.

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Framing

Water-Resistant Wall Material

Finished Wall

Whirlpool

Apply silicone sealant to the joint between the whirlpool and the finished wall.

On models with an integral apron, access the pump by gently prying at the apron edge with a screwdriver or dull knife to remove.

10. Complete the Finished Wall

NOTE: If your whirlpool has an integral apron, it is designed so the ﬁnished wall material (1-1/2″ [3.8 cm] maximum) will overlap the apron columns. The ﬁnished ﬂoor material (2″ [5.1 cm] maximum) should butt against the apron.

If you have not already done so, carefully remove the protective tape from the whirlpool rim. If necessary allow for deck-mounted valves and spout. Cover the framing with water-resistant wall material. Seal the joints between the whirlpool rim edge

and the water-resistant wall material with silicone sealant. Tape and mud the water-resistant wall material. Install the ﬁnished wall to the water-resistant wall

material. Seal the joints between the whirlpool rim and the ﬁnished wall material with silicone sealant.

Install the faucet trim according to the trim manufacturer’s instructions.

11. Removing the Apron

Your whirlpool may be equipped with an integral apron which allows you convenient access to your whirlpool controls. To remove the apron, insert the edge of a ﬂat blade screwdriver or dull knife under the edge of the apron panel. Be careful not to scratch the visible surfaces. Gently pry up at one end. Carefully pull the apron panel off.

To reinstall, bow the apron slightly so both ends can be inserted at the same time. Gently press in the center of the panel to secure the apron in place.

12. Clean-Up After Installation

When cleaning up after installation, do not use abrasive cleansers, as they may scratch and dull the whirlpool surface. Use warm water and a liquid detergent to clean the surface.

Remove stubborn stains, paint, or tar with turpentine or paint thinner. Do not allow cleaners

containing petroleum distillates to remain in contact with any whirlpool surfaces for long periods of time. Remove plaster by carefully scraping with a wood edge. Do not use metal scrapers, wire

brushes, or other metal tools. Use a powder-type detergent on a damp cloth to provide mild abrasive action to any residual plaster.

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Fill with water 2" (5.1 cm) above the highest jet.

Turn the jet trim ring clockwise to decrease the flow.

Position the jet nozzles to direct the water flow as desired.

Turn the jet trim ring counterclockwise to increase the flow.

Press the air actuator to turn on and off the whirlpool.

13. Conﬁrm Proper Operation

Fill the Whirlpool

NOTE: Please read these steps carefully before you operate your whirlpool.

Position the jet nozzles so they face down toward the basin. Turn the jet trim rings fully counterclockwise.

Fill the whirlpool to a water level at least 2″ (5.1 cm) above the top of the highest jet.

NOTE: The water temperature in the whirlpool should not exceed 104° F (40° C).

Operating Sequence

Press the air actuator to turn on the whirlpool jets. Adjust each jet for optimum air/water mixture. Turn the trim ring clockwise to reduce the air ﬂow,

and counterclockwise to increase the air ﬂow. If equipped with a heater, the heater will engage automatically when the pump is turned on and

will disengage when the pump is turned off. The heater will not turn on if the water temperature exceeds 104° F (40° C).

Press the air actuator a second time to turn off the whirlpool.

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Remove the Jets

Re-install the Jets

Insert the tool hook as shown and pull the jet out of the

Housing

housing. The jet should be facing up when this is done.

Inspect and lubricate the O-ring

Slide the O-ring onto the first shoulder of the jet

Insert the jet into the housing, and lightly push and rotate until it snaps in position

14. Troubleshooting Procedure

Remove the Factory Installed Jets

NOTE: A special tool is provided with the replacement jets that will allow you to remove the jets from the whirlpool. This tool is also supplied with each trim kit.

Position the jet ball nozzle so it is pointing upward.

NOTE: The nozzle must remain pointed up or the tool will slip off.

Insert the removal tool, hooked end up, into the opening of the jet and hook the inside top of the nozzle.

Grasp the tool ﬁrmly and place your thumb against the whirlpool wall. Pull steadily on the tool until the jet assembly pulls free of the hole. Be careful not to lose the O-ring.

Reinstall the Jets

NOTE: The jet O-ring must be correctly positioned, must be lubricated, and must be in good condition to permit easy rotation and proper operation of the jet.

Install the O-ring onto the ﬁrst shoulder of the jet. Lubricate the O-ring with silicone lubricant to prevent noisy operation of the jet.

Carefully insert the jet into the housing, and lightly push and rotate the jet until it snaps into position. Do not force the jet.

NOTE: When installed correctly, the jet should turn smoothly both clockwise and counterclockwise.

Troubleshooting Guide

This troubleshooting guide is for general aid only. A Kohler Authorized Service Representative or qualiﬁed electrician should correct any electrical problems. For warranty service, contact your dealer or wholesale distributor.

Symptoms Probable Causes Recommended Action

1. Whirlpool does not start or

stop.

2. Motor starts, not all jets are functioning.

A. No power to motor. A. Set/reset the GFCI or ELCB;

B. Air actuator does not work. B. Replace air actuator. C. Air actuator tubing is

disconnected, loose, kinked, plugged, or damaged.

D. Motor/pump does not work. D. Rebuild or replace

A. Jet is closed. A. Rotate jet trim ring

check wiring.

C. Connect, straighten, clean, or

replace air actuator tubing.

motor/pump.

counterclockwise to open.

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