Kohler K-792 User manual

Installation Guide

Bath Whirlpool with Custom Pump Option

K-792, K-809, K-852,

K-856, K-865

Mproduct numbers are for Mexico (i.e. K-12345M)

Los números de productos seguidos de Mcorresponden a México

(Ej. K-12345M)

Français, page “Français-1”

Español, página “Español-1”

1019436-2-E

Important Information

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

the following:

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

Circuit-Interrupter (GFCI) or Earth-Leakage Circuit-Breaker (ELCB).

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.

A pressure wire connector marked ″Earth/Ground″is provided within the wiring compartment. To reduce

the risk of electric shock, connect this connector to the grounding terminal of your electric service or supply

panel with copper wire equivalent in size to the circuit conductor supplying this equipment.

Pressure wire connectors are provided on the exterior of the junction box or control within this unit to permit

connection of a bonding conductor between this unit and all other exposed metal in the vicinity, as needed to

comply with local requirements.

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) or Earth-Leakage

Circuit-Breaker (ELCB). The GFCI or ELCB protect against line-to-ground shock hazard. Use a 208 - 240 V, 20

A, 50/60 Hz dedicated service for the whirlpool.

Product Notices

WARNING: Unauthorized modiﬁcation may cause unsafe operation and poor performance of the

whirlpool. This whirlpool has an optional custom pump location feature. If this option was ordered,

the pump ﬁttings are in place when you receive your whirlpool. The pump should only be moved to

this location. Do not 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.

Features

Components include a pump, heater, control and illuminated switch (user keypad).

Connections and Service Access

Before installation, ensure proper access to the ﬁnal connections.

1019436-2-E 2 Kohler Co.

Product Information (cont.)

NOTICE: Provide generous, 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

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

Electrical Requirements .......................................................... 2

Product Notices ................................................................ 2

Features ..................................................................... 2

Connections and Service Access ................................................... 2

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

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

Before You Begin ................................................................. 4

Prepare the Site ................................................................. 5

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

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

Disconnect the Pump .............................................................. 7

Relocate the Pump - Option A ....................................................... 7

Relocate the Pump - Option B ....................................................... 7

Install the Whirlpool ............................................................... 8

Mount the Pump in Custom Location .................................................. 9

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

Make Electrical Connections ........................................................ 11

Install the Whirlpool Trim Kit ........................................................ 12

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

Complete the Finished Wall/Deck .................................................... 13

Complete the Concrete Installation ................................................... 13

Clean-Up After Installation ......................................................... 13

Conﬁrm Proper Operation .......................................................... 14

Operating Sequence ............................................................. 14

Troubleshooting Procedures ........................................................ 14

Kohler Co. 3 1019436-2-E

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

Company.

Tools and Materials

Before You Begin

WARNING: Risk of personal injury. Your cast iron whirlpool is extremely heavy. Obtain sufficient

help to carefully lift and move it.

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, corner, or alcove installation.

Inspect the whirlpool for damage before you begin installation.

You must install this whirlpool to an adequately supported, level subﬂoor.

Plus:

• Conventional woodworking or concrete

installation tools and materials

• Drop cloth

• Metal shims

• 2x4's

Silicone Sealant Measuring Tape Pencil Tin Snips Level

Safety Glasses Pipe Wrench

1019436-2-E 4 Kohler Co.

1. Prepare the Site

Concrete Construction

NOTICE: Adequate ﬂoor support must be provided. Consult the roughing-in sheet packed with your

whirlpool for speciﬁc ﬂoor loading requirements.

CAUTION: Risk of product damage. 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.

This whirlpool may be installed next to the wall or in an island installation. An island installation

requires a four side surround. In both instances, make sure the deck is supported by brick or

concrete.

Install an access panel to allow the pump to be serviced.

Construct brick or concrete supports.

Provide a 1/16″(2 mm) gap between the whirlpool rim and the concrete or brick framing. Frame

the ﬂoor, or construct a frame for a raised installation, in accordance with the roughing-in

information packed with the whirlpool.

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

check for leaks.

Brick

Bath

1/16"

(2 mm)

Tile

Approved

Tile Backing

Typical

access

panel

Tile

Approved

Tile Backing

Brick

Whirlpool may be installed

next to the wall or as an

island installation.

Install an access panel to allow

the pump to be serviced.

Custom

Pump

Kohler Co. 5 1019436-2-E

2. Prepare the Site

Wood Construction

NOTICE: Adequate ﬂoor support must be provided. Consult the roughing-in sheet packed with your

whirlpool for speciﬁc ﬂoor loading requirements.

CAUTION: Risk of product damage. 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 may be used in a drop-in, corner, or alcove installation. Construct 2x4 stud framing

designed for your particular installation. Frame the ﬂoor, or construct a frame for a raised

installation in accordance with the roughing-in information packed with the whirlpool.

Use the roughing-in cut-out information to carefully lay out and cut the rough deck material.

Install an access panel to allow the pump to be serviced.

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

leaks.

3. Prepare the Whirlpool

We recommend a tiling-in bead for straight-rimmed whirlpools, if one or more sides of the

whirlpool contact a wall. This bead prevents water from seeping between the whirlpool rim and the

wall. Follow the instructions packed with the tiling-in bead to install the bead now.

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.

Construct 2x4

stud framing

according to

the roughing-in

information.

Position

the rough

plumbing.

Verify that the subfloor

offers adequate support,

and is flat and level.

Typical access panel

Frame the floor according to

the roughing-in information.

Position the

rough plumbing.

Verify that the subfloor offers adequate

support, and is flat and level.

Custom pump

access panel Typical

access

panel

1019436-2-E 6 Kohler Co.

4. Disconnect the Pump

IMPORTANT! No cutting of the whirlpool harness (pipes) is required for this installation. Any cutting

of the whirlpool harness will void the warranty.

Disconnect the pump from the whirlpool by cutting the two banding straps with a tin snips.

NOTE: The heater may be attached to the pump or already in the custom pump location, as models vary.

IMPORTANT! Two methods of pump relocation are described below. Choose the method which is best

suited for your particular whirlpool installation.

5. Relocate the Pump - Option A

Drop-in Installations

Relocate the heater and/or pump next to the customized inlet/outlet connections of the whirlpool

harness. The pump may protrude beyond the rim of the whirlpool. Refer to the roughing-in details.

Feed the supplied cable ties through the holes in the bracket attached to the backside of the

whirlpool, and located above the new pump.

Temporarily secure the pump to the whirlpool by wrapping the cable ties around the pump and

control.

Follow all procedures in the ″Install the Whirlpool″section. While moving the whirlpool into

position, the pump will be temporarily suspended. Be careful not to damage the pump and control

while guiding the whirlpool into position.

Remove the cable ties and connect the pump to the harness by following all procedures in the

″Mount the Pump in Custom Location″section.

6. Relocate the Pump - Option B

Set the pump aside.

Follow all the procedures in the ″Install the Whirlpool″section.

Through the access panel, move the pump to the new location. Connect the pump to the harness by

following all the procedures in the ″Mount the Pump in Custom Location″section.

Pump

Wiring

Harness

Rubber Isolation Feet

Control

Cut the pump banding straps.

Kohler Co. 7 1019436-2-E

7. Install the Whirlpool

WARNING: Risk of personal injury. This cast iron whirlpool is extremely heavy. Obtain sufficient help

to carefully lift and move it.

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.

Carefully move the whirlpool into position. Insert the drain tailpiece into the trap.

Level the whirlpool by ﬁtting metal shims under the whirlpool feet as needed. Check for level along

the top of the whirlpool, and across the drain side. If the feet are not accessible from the back or

side, move the whirlpool in and out of position to shim it properly. Make sure the whirlpool is

resting on all four feet.

Level by fitting metal shims

under the whirlpool feet.

1019436-2-E 8 Kohler Co.

8. Mount the Pump in Custom Location

Remove all protective packaging from around the whirlpool harness. Cut only those cable ties

supporting the harness attachment nuts.

Remove the plugs from the pump inlet and outlet openings. Install the supplied gasket in the

connection where the heater and pump join. Install the supplied O-rings/gaskets into the grooves

on the inlet and outlet connector ﬁttings.

Position the pump and control into place. Be sure the rubber isolation feet remain in place.

Thread the plastic inlet and outlet attachment nuts onto the heater and/or pump until the

O-rings/gaskets make initial contact.

Tighten each nut no more than another quarter of a turn. Do not use a wrench or overtighten these

nuts, as damage or leaks may result.

Make sure the whirlpool harness piping is pitched correctly (down and away) to promote the

drainage of water from the pump through the suction ﬁtting. The pump should rest on the same

subﬂoor, at the same level as the whirlpool feet. Shim the pump if necessary on the subﬂoor, but

only high enough to allow water to drain out of the suction line when the whirlpool is drained.

NOTE: Do not shim the pump more than 1/4″(6 mm). Raising the pump too high will prevent the pump

from priming properly.

If your heater was already installed in the custom location, simply plug the heater cord into the

heater connection on the control by aligning the pins and pressing it into place.

Locate the solid copper 8-gauge bonding wire, which has been secured to the bracket upon which

the pump has shipped. Feed this bonding wire back to the pump and control, in the custom

location, and connect to one of the open bonding lugs on the control box. This is necessary to bond

any metal back to the grounding source.

Make sure the wiring from the bath-mounted user keypad is connected to the wiring harness on the

control.

9. 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.

Relocate

Pump

Install O-rings

and/or gaskets

(supplied) into the

grooves of the

connector fittings.

Install gasket where

heater and pump join.

Make sure the water intake

pipe is pitched down and

away from the pump.

Wiring harness

Heater connection

User Keypad

Correct

Incorrect

When installing the pump, be sure to

remove the plugs from the inlet and

outlet piping.

Provide access to the

installed pump for servicing.

Kohler Co. 9 1019436-2-E

Install the Plumbing (cont.)

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

If your whirlpool requires grip rails, install them now according to the installation instructions

packed with the grip rails.

1019436-2-E 10 Kohler Co.

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