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

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Installation Guide
Drop-In 120 V 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-1196, K-1198,
K-1201, K-1209, K-1221, K-1224, K-1226, K-1231, K-1239, K-1244, K-1246, K-1248, K-1257, K-1263,
K-1266, 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 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.
Hmodels 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.
Hmodels are also supplied with a factory assembled heater. An optional timer kit is available for 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 ................................................................. 4
Prepare the Site ................................................................. 5
Prepare the Whirlpool ............................................................. 6
Secure the Unit — Models With Support Blocks .......................................... 6
Secure the Whirlpool to the Stud Framing ............................................... 8
Secure the Unit — Models With Whirlpool Base .......................................... 9
Cut the Pump Banding Straps ...................................................... 10
Install the Plumbing .............................................................. 10
Install a Rim-Mounted Faucet ....................................................... 11
Make Electrical Connections ........................................................ 12
Test Run the Whirlpool ............................................................ 13
Complete the Finished Deck ........................................................ 14
Complete the Finished Wall ........................................................ 15
Clean-Up After Installation ......................................................... 15
Confirm Proper Operation .......................................................... 15
Troubleshooting Procedure ......................................................... 17
Kohler Co. 3 1010564-2-G
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 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
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 drop-in 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.
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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: 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.
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. Provide for a 1/16(2 mm) gap between the bottom of the whirlpool rim and the stud framing for drop-in installations. 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.
Position the plumbing according to the roughing-in information packed. Cap the supplies, and check for leaks.
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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.
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
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.
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. Make sure 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. Make sure 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.
or
Apply construction adhesive to the whirlpool base.
5. Secure the Unit — 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.
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.
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.
Option Using Silicone Sealant
With help, carefully lift the whirlpool into position. 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. Ensure a watertight seal on the whirlpool drain.
Connect the drain to the trap according to the drain manufacturer’s instructions.
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
Install the faucet to the rim and plywood according to the faucet
manufacturer's instructions. the K-1226, or 4" (10.2 cm) x 15-1/2" (39.4 cm) for the K-1331.
8. Install a Rim-Mounted Faucet
K-1226 and K-1231 Only
Measure and cut a piece of 1/2exterior grade plywood 4(10.2 cm) x 11-1/2(29.2 cm) for the K-1226, or 4(10.2 cm) x 15-1/2(39.4 cm) for the K-1231.
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, and the K-1231 will accept faucets with 4 (10.2 cm) or 6(15.2 cm) centers.
CAUTION: Risk of product damage. 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.
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-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.
Bond in accordance with applicable codes.
NOTE:
Pump model illustrated may differ from your actual product.
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. 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
HModels: 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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Fill with water 2" (5.1 cm) above the highest jet.
Turn the jet trim ring clockwise to decrease the flow.
Turn the jet trim ring counterclockwise to increase the flow.
Position the jet nozzles to direct the water flow as desired.
Press the air actuator to turn the whirlpool on or off.
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. 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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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.
14. 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).
To service orifices insert a pencil into the end of the jet nozzle and push the orifice out. After removing any blockage, check the orifice to make sure it is clear and press it into the jet housing.
NOTE: Orifices are only installed in whirlpool jets when there are six or more jets in the whirlpool system.
Operating Sequence
Press the air actuator to turn on the whirlpool jets.
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Confirm Proper Operation (cont.)
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.
15. 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.
A. No power to motor. A. Check that the pump and heater
are plugged in and that the GFCI or ELCB is switched to the correct position. Plug in or reset the GFCI/ELCB as needed.
B. Air hose is loose or disconnected. B. Check that the hose is connected
at both the receiver/pump end and to the air switch. Reconnect if needed.
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Troubleshooting Procedure (cont.)
Symptoms Probable Causes Recommended Action
C. Air hose is pinched or kinked. C. Adjust hose to clear the
D. Part(s) of the push button
assembly is/are damaged.
E. Push button has grease in the
bleed area.
F. Air hose is not properly installed
to the optional timer kit, or the pump is in the offposition.
G. Air hose is damaged. G. Replace the air hose. H. Motor/pump does not work. H. Rebuild or replace motor/pump.
2. Motor starts, not all jets
are functioning.
3. Whirlpool stops
automatically before 18 minutes.
4. Pump does not prime.
(Models with support blocks only.)
5. Noisy operation. A. Pump banding straps have not
6. Heater does not operate.
(“H” models only)
A. Jet is closed. A. Rotate jet trim ring B. Jet not installed correctly. B. Reinstall jet; check for O-ring C. Jets are blocked. C. Remove blockage.
A. The GFCI or ELCB trips. A. Identify source of fault, and
B. Suction blocked. B. Remove obstruction. C. Jets are blocked. C. Remove blockage. D. Motor overheated and protection
device activated.
A. Pump shimmed too high. A. Lower pump support bracket.
been cut. (Models with support blocks only.)
B. Jet O-ring dislodged. B. Remove jet, replace and lubricate A. No power to heater. A. B. Water temperature exceeds 104°F
(40°C).
C. Heater does not work. C. Replace heater.
pinched/kinked area. If the tubing is pinched/kinked and cannot be readjusted, or no noticeable pinch/kink is apparent, poke a small hole in the tubing with a tack and try the system again.
D. Replace the push button
assembly.
E. Disassemble the push button
assembly and wipe away any excess grease. Reassemble the button and retry the system.
F. Refer to the timer kit installation
instructions to check the timer kit installation. Contact the installer/dealer.
counterclockwise to open.
damage.
correct.
D. Check for blockage at motor
vents. Remove blockage and allow motor to cool. Check for suction blockage. Remove blockage and allow motor to cool. Check for jet blockage. Remove blockage and allow motor to cool.
A. Cut pump banding straps with
tin snips.
O-ring, and reinstall jet. Reset the GFCI or ELCB.
B. Allow water to cool and heater
will reengage.
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