Kohler K1162H47 Installation Manual

Installation Guide

Drop-In Bath Whirlpool

K-1106, K-1112, K-1114, K-1126, K-1131, K-1139, K-1144, K-1146, K-1148, K-1154, K-1157, K-1160, K-1162, K-1164, K-1192,

K-1194, K-1201, K-1209, K-1221, K-1224, K-1226, K-1239, K-1244, K-1246, K-1248, K-1257, K-1263,

K-1337

M product numbers are for Mexico (i.e. K-12345M) Los números de productos seguidos de M corresponden a México (Ej. K-12345M) Français, page ″Français-1″ Español, página ″Español-1″

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Important Information

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

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 qualiﬁed 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) or Residual Current Device (RCD). The GFCI or RCD 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 replaced.

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.

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

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

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

beginning installation.

NOTICE: Follow all local plumbing and electrical codes.

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. 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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Product 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 Guide packed with the whirlpool.

Table of Contents

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

Product Information ............................................................... 2

Tools and Materials ............................................................... 3

Before You Begin ................................................................. 3

Prepare the Site ................................................................. 4

Prepare the Whirlpool ............................................................. 5

Secure the Unit — Models With Support Blocks .......................................... 5

Secure the Whirlpool to the Stud Framing ............................................... 7

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

Cut the Pump Banding Straps ...................................................... 10

Install the Plumbing .............................................................. 10

Install a Rim-Mounted Faucet ....................................................... 11

Make Electrical Connections ........................................................ 12

Test Run the Whirlpool ............................................................ 12

Complete the Finished Deck ........................................................ 13

Complete the Finished Wall ........................................................ 14

Clean-Up After Installation ......................................................... 14

Conﬁrm Proper Operation .......................................................... 15

Troubleshooting ................................................................. 16

Tools and Materials

Silicone Sealant

Safety Glasses

Tape Measure

Pipe Wrench

Pencil

Level

Before You Begin

Inspect the whirlpool for damage before you begin installation.

Plus:

• Conventional woodworking tools and materials

• Drop Cloth

• Construction adhesive (optional)

• Cement or mortar (optional)

• 2x4s or 2x6s

• Screws or Lag Bolts

Conﬁrm adequate mounting and connection space for the faucet speciﬁed for your installation. Kohler Co. reserves the right to make revisions in the design of products without notice, as speciﬁed

in the Price Book.

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Whirlpool Rim

Drop-In Installation

Allow for the thickness of the planned deck material.

Whirlpool Rim

Wood Batten

Do not support the whirlpool by the rim.

Use the roughing-in information to construct the stud framing.

Whirlpool Rim

Use the roughing-in information to construct the stud framing.

Flush Installation

Tiled Ledge Installation

1. Prepare the Site

NOTICE: Refer to the Roughing-in Guide packed with your whirlpool for the required minimum lb/square foot (kg/square meter) ﬂoor support loading.

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

NOTICE: The whirlpool should be installed in a drop-in, ﬂush, or tiled ledge installation.

Construct 2x4 or 2x6 stud framing designed for your particular installation.

NOTICE: The whirlpool must be supported by its feet or base. Do not support the load weight of the whirlpool by the perimeter of the rim.

For a raised installation: Frame the ﬂoor or construct a frame 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 Guide for cutout information.

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

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Frame the floor

Position the rough plumbing.

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

according to the roughing-in information.

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

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.

3. Secure the Unit — Models With Support Blocks

NOTICE: Do not lift the whirlpool by the piping or pump, or use the piping or pump for structural support of the whirlpool. To avoid damage to the whirlpool, lift at the sides of the whirlpool.

NOTICE: Do not support the load weight of the whirlpool by the perimeter of the rim. The rim perimeter must be adequately supported, but must not support the load weight of the whirlpool.

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

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

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.

Secure the drain tailpiece to the trap. Ensure the whirlpool is level and resting on all support blocks. Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant

around the entire rim of the whirlpool.

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.

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Secure the Unit — Models With Support Blocks (cont.)

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

Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant around the entire rim of the whirlpool.

Option Using Silicone Sealant

With help, carefully lift the whirlpool into position. Insert the drain tailpiece into the trap. Ensure the whirlpool is level and resting on all support

blocks. Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant

around the entire rim of the whirlpool.

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Stud Framing

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

Drill a small pilot hole through the nailing-in flange.

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

Install a pressure-treated wood batten along the nailing-in flange.

Stud Framing

4. Secure the Whirlpool to the Stud Framing

Option for Integral Flange Models

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. For tile ledge installations, size and install a pressure-treated wood batten along the nailing-in

ﬂange. Pre-drill nail holes through the wood batten and nailing-in ﬂange before securing with galvanized nails.

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

Apply a bead of silicone sealant around the entire rim.

Apply construction adhesive to the whirlpool base.

5. Secure the Unit — Models With Whirlpool Base

NOTICE: Do not lift the whirlpool by the piping or pump, or use the piping or pump for structural support of the whirlpool. To avoid damage to the whirlpool, lift at the sides of the whirlpool.

NOTICE: Do not support the load weight of the whirlpool by the perimeter of the rim. The rim perimeter must be adequately supported, but must not support the load weight of the whirlpool.

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 (not provided) to secure the whirlpool base to the ﬂoor. Drill small pilot holes through the whirlpool base as needed.

Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant around the entire rim of the whirlpool.

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.

Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant around the entire rim of the whirlpool.

Option Using Silicone Sealant

With help, carefully lift the whirlpool into position.

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Secure the Unit — Models With Whirlpool Base (cont.)

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.

Remove the protective tape from the rim. Apply a continuous bead of high-quality silicone sealant around the entire rim of the whirlpool.

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Pump

Cut the pump banding straps.

Drainage

NOTE:

Pump model illustrated may differ from your actual product.

Suction Line

6. Cut the Pump Banding Straps

NOTE: If your pump model does not have banding straps, proceed to the next section.

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. A watertight seal must exist on the whirlpool drain. The watertight seal will prevent property damage.

NOTICE: An access panel will simplify future maintenance.

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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Whirlpool Rim

4" (10.2 cm)

Measure, cut, and drill a piece of 1/2" exterior grade plywood 4" (10.2 cm) x 11-1/2" (29.2 cm) for the K-1226.

Install the faucet to the rim and plywood according to the faucet manufacturer's instructions.

8. Install a Rim-Mounted Faucet

K-1226 Only

Measure and cut a piece of 1/2″ exterior grade plywood 4″ (10.2 cm) x 11-1/2″ (29.2 cm) for the K-1226.

The faucet should be located in the center of the ﬂat area of the rim. Refer to the faucet manufacturer’s instructions. Use a pencil to mark the faucet centerlines for drilling.

NOTE: The K-1226 will accept faucets with 4″ (10.2 cm) centers.

NOTICE: Position a thin piece of cardboard on the ﬁnished surface of the whirlpool before clamping the

plywood in place. Make sure the clamps do not make direct contact with the ﬁnished surface of the whirlpool. This will reduce the risk of damaging the surface of the whirlpool.

Set a thin piece of cardboard on the ﬁnished surface of the whirlpool rim. Position the plywood on the bottom of the rim, and carefully clamp the plywood in place. Make sure the clamps are in contact with the cardboard, not the ﬁnished surface of the whirlpool.

Carefully drill the faucet holes to the size required by the faucet manufacturer. Remove the clamps and cardboard.

Install the faucet to the rim and plywood according to the faucet manufacturer’s instructions. 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- or RCD-protected 120 V, 15 A grounded outlet. Install a second GFCIor RCD-protected outlet for "H" models for the heater.

Optional Heater either T-style (shown) or water intake

(not shown).

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

Bond in accordance with applicable codes.

NOTE:

Pump model illustrated may differ from your actual product.

(models may vary)

Plug pump and heater into these outlets.

9. Make Electrical Connections

WARNING: Risk of electric shock. Make sure the power has been disconnected before performing the following procedures.

WARNING: Risk of electric shock. Connect the pump and in-line heater (if included) to properly grounded, grounding-type receptacles protected by Ground-Fault Circuit-Interrupters (GFCI’s) or Residual Current Devices (RCD’s). Do not remove the grounding pins from the plug. Do not use grounding adapters.

NOTE: A label identifying the model number and electrical rating of the whirlpool is located near the whirlpool pump.

NOTICE: The pump (supplied) and heater (if supplied) are equipped with a cord and plug. All wiring for the heater has been completed at the factory. A qualiﬁed electrician must install a GFCI- or RCD-protected, 120 V, 15 A, grounded outlet. No other load should be on this circuit.

Pump Wiring

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.

Heater Wiring – “H” Models

Locate the outlet behind the whirlpool, and within 24″ (61 cm) of the heater. Plug the heater into this outlet.

10. 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. Refer to ″Conﬁrm

Proper Operation″ section for additional information. Operate the whirlpool for 5 minutes, and check all whirlpool piping connections for leaks.

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Finished Deck Material

Whirlpool

Apply silicone sealant to the edges of the water-resistant deck material and the finished deck

Water-Resistant Deck Material

Framing

11. Complete the Finished Deck

If you have not already done so, carefully remove the protective tape from the whirlpool rim. Cover the framing with water-resistant deck material. Seal the joints between the whirlpool rim

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

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

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

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Install the finished ledge material.

First install water-resistant wall material.

Framing

Finished Ledge

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

Whirlpool Flange

Install the finished wall material.

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

12. Complete the Finished Wall

Tiled Ledge Installation

If you have not already done so, carefully remove the protective tape from the whirlpool rim. Cover the framing with water-resistant wall material. 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 instructions packed with the trim.

13. 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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Turn the jet trim ring clockwise to decrease the flow.

Fill with water at least 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.

14. Conﬁrm Proper Operation

Fill the 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

Reinstall the Jets

Insert the tool hook as shown and pull the jet out of the housing. The jet should be facing up when this is done.

Housing

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.

Troubleshooting

NOTICE: This section 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.

Remove the 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: To allow easy rotation and proper operation of the jet, the O-ring must be: (1) correctly positioned, (2) lubricated, and (3) in good condition.

Install the O-ring onto the ﬁrst shoulder of the jet. Using the silicone lube packet (provided), lubricate the O-ring to prevent noisy operation of the jet. Carefully insert the jet into the housing, then lightly push and rotate the jet until it snaps into

position. Do not force the jet. Verify the jet is installed correctly. The jet should turn smoothly both clockwise and

counterclockwise. Remove and reinstall, if necessary.

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Troubleshooting (cont.)

Symptoms Probable Causes Recommended Action

1. Whirlpool

will not start/stop.

2. The system

will start but will not stay ON.

3. Whirlpool

stops automatically.

4. The motor

starts but not all jets function.

5. Noisy pump

operation.

6. Heater does

not operate (units with heaters only).

A. No power to pump. A. Verify pump is plugged in and the

B. Remove the access panel and press

the air switch, if you do not hear a ″click,″ the air switch tubing is loose or disconnected.

C. Air switch tubing is pinched or

kinked.

D. Push button assembly is damaged. D. Replace the push button assembly. E. Pump has power and a ″click″ is

heard when the air switch is pressed. Pump is not operating.

F. The receiver in the pump is not

operating.

A. The receiver in the pump is not

operating.

A. Pump has overheated and the

protection devices have activated.

B. GFCI/RCD circuit has tripped. B. Identify source fault and correct. Check

A. Jets are closed. A. Rotate the jet trim ring counterclockwise

B. Jets are blocked or trim ring rotation

is impeded.

C. Jets not installed correctly. C. Reinstall the jet; check for any O-ring

D. Pump is not supported correctly and

is cavitating.

A. The pump banding straps have not

been cut (models with support blocks only).

A. No power to heater or it is not

connected to a separate outlet from the pump.

B. The water temperature is above 104°F

(40°C).

GFCI/RCD is not tripped. Verify the outlet has power using a multi-meter or by connecting a 110V item that you know is working (lamp, radio, etc.) into the outlet. Repair as needed.

B. Check if the air switch tubing is connected

at both the receiver/pump end and the air switch. Reconnect if needed.

C. Adjust tubing to clear the pinched/kinked

area. If the pinch/kink cannot be ﬁxed, or no noticeable pinch/kink is apparent, puncture the tubing with a tack and try the system again.

E. Replace the pump.

F. Replace the receiver or pump.

A. Replace the receiver or pump.

A. Check for blockage at the motor vents.

Check for suction blockage. Check for jet blockage. Remove any blockage and allow the motor to cool.

that the GFCI/RCD has not been tripped. If problem persists, contact a qualiﬁed electrician.

to open/increase ﬂow to the jets.

B. Glue may be obstructing the jet opening

or preventing the jet trim ring from rotating. Remove the trim ring and remove excess glue.

damage.

D. Review the installation instructions and

verify that the pump is at the appropriate height and that the pump banding straps (when applicable) have been cut.

A. Using tin snips, cut pump banding straps.

A. Verify that the heater is connected to a

separate outlet from the pump and that the connection has power.

B. As a safety precaution, the heater will not

operate when the water temperature is above 104°F (40°C).

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