Kohler STERLING 7610 Series User manual

Installation Guide
Whirlpool Bath and Wall Surrounds
Français, page “Français-1”
Español, página “Español-1”
7610, 7611 Series
1016902-2-F

Installation Instructions
WARNING: When using electrical products, always follow basic precautions, including the
following:
DANGER: Risk of electric shock. To reduce the risk of electrical shock, connect the pump or
blower only to a properly installed Ground-Fault Circuit-Interrupter (GFCI). Do not remove the
plug grounding pin. Do not use a grounding adapter.
WARNING: Risk of injury or property damage. Please read all instructions thoroughly before
beginning the installation, including the following requirements.
WARNING: Risk of electric shock. A qualified electrician should make all electrical connections.
WARNING: Risk of electric shock. Disconnect power before servicing.
Building materials and wiring should be routed away from the pump or blower body and other
heat-producing components of the unit.
Grounding is required. The unit should be installed by a qualified service representative and grounded.
Install to permit access for servicing.
An equipment grounding terminal is provided in the field wiring compartment. To reduce the risk of electric
shock, this terminal must be connected to the grounding means provided in the electric supply panel with a
conductor equivalent in size to the circuit conductors supplying this equipment.
Install this unit in accordance with the Canadian Electrical Code, Part I.
NOTE: Follow all local plumbing, building, and electrical codes.
Product Information
Electrical Requirements
NOTE: If the 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 installation must include 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.
Product Notices
WARNING: Unauthorized modification of the pump 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. Sterling Plumbing 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, air switch transmitter, and whirlpool
jets with suction fitting.
Connections and Service Access
Before installation, verify proper access to the final connections.
1016902-2-F 2 Sterling

Tools and Materials
Before You Begin
NOTICE: Risk of product damage. The wall surround sections are backed with foam to bring the back of
the wall into contact with the stud framing. This foam is not packing material. Do not remove.
NOTICE: Risk of product damage. Do not install the whirlpool over open floor joists. The basin area
requires no additional support when the subfloor is level and square with the stud framing. Install the
whirlpool on an adequately supported, level subfloor. Use shims for additional support if the subfloor is
uneven.
Observe all applicable plumbing, electrical, and building codes.
This whirlpool is designed for alcove installations.
Upon receipt, check for shortages or damage. Report any shortages or damage immediately.
Do not remove the old fixture before you unpack and inspect the new unit.
Store the whirlpool and wall surrounds in a safe place until you begin installation to avoid damage.
If remodeling, measure the existing framework before removing the old whirlpool to make sure that
the new whirlpool will fit. Make sure that the drain is in the correct location.
Confirm adequate mounting and connection space for the water supply and drain installation.
If your whirlpool is shipped with a liner, keep the liner in place until construction is complete. If a
liner is not available, position a clean drop cloth or similar material in the bottom of the whirlpool.
If you encounter any installation or performance problems, please do not hesitate to contact Sterling
at 1-888-STERLING in the USA or 001-877-680-1310 in Mexico.
Sterling reserves the right to make revisions in the design of products without notice, as specified in
the Price Book.
Plus:
Tin Snips
Clear 100%
Silicone Sealant
• Conventional woodworking
tools and materials
• Drop cloth
• Mortar cement (recommended)
• 1x4s, and 2x4s or 2x6s
• Hole saw
• Galvanized or plated non-tapered
flathead screws
• Furring Strips
Sterling 3 1016902-2-F

Roughing-In
ABCDE F G
76100100 60″
(1524 mm) 8-3/4″ (222 mm) 37-1/2″ (953 mm) 17-1/4″ (438 mm) 73-1/4″ (1861 mm) 8-3/4″ (222 mm) 24-1/2″ (622 mm)
76110100 60″
(1524 mm) 8-3/4″ (222 mm) 43-1/2″ (1105 mm) 20-1/4″ (514 mm) 73-1/4″ (1861 mm) 11-1/2″ (292 mm) 27-1/2″ (699 mm)
IMPORTANT! Dimensions given in the roughing-in information are critical for proper installation.
Construct the framing and plumbing accurately.
IMPORTANT! All dimensions are nominal. The stud opening tolerance is plus 1/8″(3 mm) and minus 0.
IMPORTANT! Unless otherwise specified, the floor support under the whirlpool must provide a minimum
of 80 pounds per square foot (390 kilograms per square meter) loading.
NOTE: If a firewall is required, roughing-in dimensions must be increased according to the thickness of
the firewall material. Stud opening dimensions must be measured toward the exposed side of the wall
material.
NOTE: If installing this unit to a masonry wall, make provisions for plumbing connections. Construct a
separate frame wall at least 6″(152 mm) from the masonry wall.
The whirlpool and optional wall surrounds can be installed directly to the framing studs, over wallboard, or
over other water-resistant material. When installing over wallboard or other water-resistant wall material, the
framing dimensions must be increased to accommodate the material thickness.
For whirlpools with wall surrounds, installing accessories that require backing or support is not
recommended.
30" (762 mm) 30" (762 mm)
4" (102 mm)
C
G
F
B
D
8" (203 mm) B
D
A
A
C
E
6"
(152 mm)
Drain
Cutout
3-1/2" (89 mm)
Ø 2" (51 mm)
Drain
Recommended Support
Clip Location (4 Total)
Diagrams shown are representative and for use with the table only.
Your fixture may appear different from the illustrations.
14"
(356 mm)
14"
(356 mm)
1016902-2-F 4 Sterling

1. Construct the Framing
Install the Framing
IMPORTANT! Dimensions given in the roughing-in information are critical for proper installation. Refer to
the ″Roughing-In″section for dimensions.
IMPORTANT! For installations with wall surrounds, provide support for the vertical wall flanges at
37-1/4″(946 mm) or 42-1/4″(1073 mm), depending upon the specific model.
IMPORTANT! The framing for each stud should be plumb and square to within 1/8″(3 mm). Shimming
may be required.
Carefully measure the whirlpool.
Construct 2x4 framing using the dimensions specified in the ″Roughing-In″section.
If possible, remove the bottom plate.
Construct an access panel to allow access for servicing the faucets and drain.
IMPORTANT! For installations with wall surrounds, do not allow fiber or other soft insulation to drop
down into the back channel, as this could damage the whirlpool.
For installations with wall surrounds, cover or seal any loose material.
NOTE: If the apron flanges will not be used or have been accidentally broken off during shipping, install
three evenly distributed 2x4 blocks behind the apron location. The blocks will prevent the apron from
being damaged and may be used to secure the apron behind a baseboard.
Construct the Floor
IMPORTANT! Construct the floor of plywood. If the whirlpool is installed over material other than
plywood, friction may cause squeaking over time.
If the subfloor is constructed of a material other than plywood, position the supplied felt pad so all
supports will rest on it.
Verify that the apron flanges can be secured to studs, or install three 2x4 blocks behind the apron
location.
NOTE: The ″Roughing-In″section indicates the location of the drain.
Cut a hole in the floor large enough to fit the drain assembly selected for your installation.
Sterling 5 1016902-2-F

2. Install the Rough Plumbing
NOTE: Provide access to all plumbing connections to simplify future maintenance.
Locate the rough plumbing for the drain according to the roughing-in dimensions.
NOTE: If the plumbing will be installed on the unfinished stud wall, install the supplies after the
surround walls are installed.
Position the water supplies according to the roughing-in information. Cap the supplies and check
for leaks.
Strap the supply lines to the stud framing.
Install the valves according to the manufacturer’s instructions. Do not install the trim at this time.
Shower Elbow
Blocking
Shower Riser
Supply Valves
Blocking
Spout Elbow
Supply Lines
Optional
Series 7610, 7611
17-1/4"
(438 mm) 8-3/4"
(222 mm)
22"
(559 mm)
76-1/2"
(1943 mm)
1016902-2-F 6 Sterling

3. Install the Electrical Outlet
CAUTION: Risk of personal injury. Do not turn on the power until instructed to do so.
NOTE: The whirlpool is equipped with a cord and plug. All pump and control wiring has been completed
at the factory.
NOTE: Refer to the label near the pump. This label identifies the electrical rating and model number of the
whirlpool.
Install a GFCI-protected, 120 V, 15 A grounded outlet behind the whirlpool and within 24″(610 mm)
of the pump location. No other load should be on this circuit.
Install a bonding (grounding) conductor at the future location of the pump in accordance with any
applicable local codes.
Bond in accordance
with applicable codes.
Install a GFCI-protected 120 V,
15 A grounded outlet.
Sterling 7 1016902-2-F

4. Prepare the Whirlpool
Remove the Apron Access Panel
Insert a flat-blade screwdriver or other prying tool into one of the screwdriver slots.
Use the screwdriver to pry the bottom clip out and release the clip.
Repeat this procedure at the remaining screwdriver slots.
When all bottom clips are released, pull the bottom of the panel away from the apron to release the
remaining clips.
When the bottom of the panel is clear, lower the panel until the top of the panel is clear.
Store the panel in a safe place.
Prepare the Whirlpool
Place a clean drop cloth or similar material in the bottom of the whirlpool.
Install the whirlpool drain and overflow to the unit according to the drain manufacturer’s
instructions. Do not connect the trap at this time.
If the subfloor is not constructed of plywood, position the provided felt pad so the whirlpool
supports will rest on it.
IMPORTANT! Risk of product damage. Do not lift the whirlpool by the apron or apron braces, or by the
piping or pump. Do not use the piping or pump for structural support of the whirlpool.
IMPORTANT! Ensure that each apron brace is connected at all bosses.
IMPORTANT! Use care to properly position the whirlpool in the alcove, as proper placement is critical for
attachment to the studs. Clear all material away from the pump support bracket area and the whirlpool
supports. The pump support bracket and the whirlpool supports must rest directly on the subfloor.
Carefully lift the whirlpool into place.
Make sure the pump support bracket and whirlpool supports do not rest in the bed material.
Verify that the whirlpool is properly positioned with respect to the intended finished wall.
Depending on the installation, the outer edge of the whirlpool should be flush with the intended
finished wall at floor level.
Verify that the whirlpool is level and resting on all supports. The whirlpool should be within 1/8″
(3 mm) of level from side to side, and within 1/4″(6 mm) of level lengthwise. If the whirlpool is
not level, remove the whirlpool and place shims under the supports.
Clip
Nine Clip Locations
Four Screwdriver Locations
Apron Panel
Center Clip
Apron Frame
1016902-2-F 8 Sterling

Prepare the Whirlpool (cont.)
Install a Mortar Bed (Recommended)
Remove the whirlpool from the alcove.
NOTE: The whirlpool supports must rest directly on the subfloor.
Build a dam to keep the flooring material clear of the drain area.
NOTE: Do not use gypsum cement or drywall compound for this application, as they will not provide
adequate support.
NOTE: Do not spread mortar around the whirlpool supports.
Spread a 2″(51 mm) layer of mortar on the subfloor.
Remove the dam.
Move the whirlpool into position.
Make sure the pump support bracket does not rest in the bed material.
Verify that the whirlpool is level and resting on all supports.
Sterling 9 1016902-2-F

5. Secure the Whirlpool to the Stud Framing
This whirlpool is designed for installation into regularly spaced framing. If there is a gap between the edge
of the whirlpool and the stud, then add shimming to the stud to bring the stud to within 1/8″(3 mm) of the
whirlpool.
CAUTION: Risk of property damage. Do not nail or drill through the whirlpool flange, as this may
crack the flange and cause leaks.
Position the bottom lip of the attachment clip at the side of the stud and under the edge of the
whirlpool. Slide the adjustment clip into place between the center of the stud and the whirlpool.
Bend the tab of the clip over the whirlpool flange with a pair of pliers.
Secure the attachment clip to the center of the stud using either large-head roofing nails or
non-tapered flathead screws.
Whirlpool Flange
Apron Flanges
(if applicable)
Nail
Stud
Whirlpool
Attachment
Clip
1016902-2-F 10 Sterling

6. Cut the Pump Banding Straps
IMPORTANT! This step is necessary to make your whirlpool operate more quietly.
IMPORTANT! 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.
Cut the two pump banding straps from the whirlpool pump with a pair of tin snips. Discard the
banding straps.
Make sure the pump is not in direct contact with the whirlpool harness.
7. Connect the Drain
Connect the drain to the trap according to the manufacturer’s instructions.
Check the drain connections for leaks.
Drainage Suction Line
Pump
Cut the pump
banding straps.
NOTE:
Pump model illustrated may differ from your
actual product.
Sterling 11 1016902-2-F

8. Make Electrical Connections
Make Connections
WARNING: Risk of electric shock. To reduce the risk of electrical shock, connect the pump only to
a properly installed Ground-Fault Circuit-Interrupter (GFCI). Do not remove the plug grounding
pin. Do not use a grounding adapter.
Verify that the air actuator tubing is securely attached to the pump and to the air switch button in
the whirlpool.
Make sure the tubing is not kinked or damaged, and that the tubing slips into place on adapters at
the switch and at the pump.
Visually inspect the whirlpool pump and piping harness for damage.
Verify that the bonding conductor is connected to the pump in accordance with the applicable
codes.
Plug the electrical cord into the GFCI outlet.
Test Run the Whirlpool
For additional information on whirlpool operation, see the ″Confirm Proper Operation″section of this guide.
CAUTION: Risk of property damage. Do not fill the whirlpool above the bottom of the overflow
drain. Doing so may cause the whirlpool piping to leak. The whirlpool is not designed to hold
water above the overflow.
Check all electrical connections and make sure the electrical power to the whirlpool is turned on.
Verify that the pump banding straps have been cut.
Fill the whirlpool with water to at least 2″(51 mm) above the top of the highest jet.
Operate the whirlpool for 5 minutes. Check all whirlpool piping connections for leaks.
Turn off the whirlpool, then drain.
Plug the
pump into
the outlet.
1016902-2-F 12 Sterling

9. Pre-Fit the Wall Surrounds
IMPORTANT! Do not secure the walls to the stud framing until instructed to do so.
NOTE: If the shower valves or controls prevent the plumbing wall section from being properly positioned
before the necessary holes are cut, cut the holes according to the ″Cut Holes for the Valves and Spout″
section and then return to this procedure.
NOTE: When installing the back wall, fit the back wall tabs into the whirlpool alignment channels, as
shown.
Position the back wall on the whirlpool.
Temporarily secure the back wall over the whirlpool flange with a roofing nail or other fastener.
Install the fastener so that it can be removed easily. Do not drive the nail in so far that it prevents
the back wall from positioning properly when the end walls are installed.
Attach the two end walls to the back wall. Slide the end wall pins into the back wall interlock slots.
Verify that the assembled wall surround is resting properly on the whirlpool. If the wall surround
needs to be adjusted, remove the roofing nail at the back wall.
Verify that the end walls are flush with the edge of the whirlpool. If necessary, shift the end walls
until they are flush.
Verify that the wall sections are properly aligned with the studs at the upper and vertical wall
flanges.
End Wall Back Wall End Wall
Whirlpool
Whirlpool
Alignment
Channel
Back Wall
Interlock
Slot
Roofing Nail
End Wall Pin
End Wall
Whirlpool
Back Wall/End Wall Tab
Back Wall Flange
Sterling 13 1016902-2-F

10. Cut Holes for the Valves and Spout
Determine and mark the location for the mixing valve, shower, and bath spout holes on the back
surface of the surround wall.
Protect the bottom of the unit with a clean drop cloth.
Drill 1/4″(6 mm) pilot holes at the marked locations.
IMPORTANT! If using a round hole saw or a saw that cuts on the push stroke to cut the holes, cut the
holes from the front, or finished side of the wall. If using a jigsaw or other reciprocating saw that cuts on
the pull stroke, cut the holes from the rear of the wall.
Carefully cut the fixture holes.
Clean any debris from the whirlpool to reduce the risk of surface damage. Be careful not to scratch
the surface of the unit.
2. Drill pilot holes. 3. Cut holes.
1. Mark center of
valves and spout.
1016902-2-F 14 Sterling

11. Apply Silicone Sealant
IMPORTANT! Use clear 100% silicone sealant. Latex, caulk, or siliconized latex sealants do not provide
water and mildew resistance over the life of the product.
IMPORTANT! Do not allow the sealant to set before the end walls are installed. After applying sealant,
immediately proceed to the ″Install the Wall Surrounds″section of this guide.
Clean and dry the outer few inches of the whirlpool flange where the end walls will be installed.
Apply an L-shaped bead of clear 100% silicone sealant at each outer end of the flange where the
end walls will be installed. Apply the bead so it is 1/4″(6 mm) wide and 1″(25 mm) by 4″(102
mm) long, as shown in the illustration.
4" (102 mm)
1"
(25 mm)
1/4" (6 mm)
Apply clear 100%
silicone sealant
before installing
walls.
Sterling 15 1016902-2-F

12. Install the Wall Surrounds
Secure the Wall Surrounds
Attach the end wall to the back wall by engaging the wall interlocks and wall tabs.
Remove the temporary nail from the top of the back wall flange.
CAUTION: Risk of property damage. Wall surrounds must rest within 1/32″(1 mm), or the
thickness of a credit card, from the whirlpool rim to prevent leakage.
Verify that the walls are seated firmly on the whirlpool, and that the back wall interlocks are
engaged.
Make sure the front edges of the end walls are flush with the front edge of the whirlpool. If there is
a gap, pull the end walls slightly forward to eliminate the gap.
CAUTION: Risk of property damage. If using screws rather than nails, use non-tapered flathead
screws. Do not overtighten. Excessive tightening can damage the flange, and may cause leaks.
Starting from the bottom of the end walls and working up, secure the end walls with large-head
roofing nails or non-tapered flathead screws at the dimples on the vertical wall flanges.
Secure the flanges across the top of the wall panels at every stud location.
Seal the Wall Surrounds
NOTE: When applying water-resistant wall material over the whirlpool flanges, maintain a 1/8″(3 mm)
gap between the wall surround and the wall material. This gap serves as a contact barrier if water should
ever seep behind the applied sealant.
Cover the flanges around the wall surrounds and the whirlpool with water-resistant wall material,
leaving a 1/8″(3 mm) gap between the flanges and the wall material.
Seal the gap between the flanges and the wall material with clear 100% silicone sealant. Allow the
sealant to cure according to the manufacturer’s instructions.
Apply clear 100% silicone sealant between the whirlpool and the finished wall material to seal the
joints.
Wall Flange
Shim if
necessary.
Roofing Nail
or Screw
Stud
Roofing Nail
or Screw
Whirlpool
Flange
Rim
1/32" (1 mm)
Wall Surround
Stud
1016902-2-F 16 Sterling

13. Complete the Finished Wall
NOTE: Locate and size the holes for the valves, shower control, spout, and/or shower in the walls
according to the manufacturer’s requirements.
IMPORTANT! When applying the water-resistant wall material over the whirlpool flange, leave a 1/4″(6
mm) gap between the whirlpool rim edge and the wall material. This gap helps to reduce the possibility
of water seeping into the wall material.
Brush all dust and debris from the whirlpool flange.
Cover the framing with water-resistant wall material.
Seal the 1/4″(6 mm) gap between the whirlpool rim edge and the water-resistant wall material with
100% silicone sealant.
Install the finished wall over the water-resistant wall material.
14. Finish the Installation
CAUTION: Risk of property damage. Make sure a watertight seal exists around the whirlpool
drain and overflow, or the whirlpool may leak.
For All Installations
Apply clear 100% silicone sealant to all openings around the valves and outlets before installing the
cover plates or flanges. Allow the sealant to cure.
Install the faucet trim according to the manufacturer’s instructions.
Remove the protective covering from the basin of the whirlpool.
Apply clear 100% silicone sealant between the whirlpool and the finished floor or baseboard.
Allow the sealant to cure according to the manufacturer’s instructions.
For Miscellaneous Accessory Installations
CAUTION: Risk of property damage. Do not make additional holes in the wall surround or
whirlpool without adding adequate clear 100% silicone sealant. Additional holes made to install any
accessories may cause leakage.
NOTE: For installations with wall surrounds, install the shower curtain rod above the top of the wall
surrounds.
Install any accessories according to the manufacturer’s instructions.
Finished Wall
Clear 100%
Silicone Sealant
Water-Resistant
Wall Material
Whirlpool Flange
1/4" (6 mm) 1/4" (6 mm)
Whirlpool Flange
Water-Resistant
Wall Material
Clear 100%
Silicone Sealant
Tile or Other
Wall Finish
Whirlpool with Water-Resistant
Wall Material and Finished Wall
Whirlpool with Tile,
Marble, Etc.
Sterling 17 1016902-2-F

Finish the Installation (cont.)
Verify that all holes in the finished wall are properly sealed with 100% silicone sealant.
1016902-2-F 18 Sterling

15. Confirm Proper Operation
Installation Checkout
Verify all electrical connections.
Verify that the pump banding straps have been cut.
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 at least 2″(51 mm) above the top of the highest jet.
Operating Sequence
NOTE: If you encounter problems with the operating sequence, refer to the ″Troubleshooting″section.
Press the air switch to turn on the whirlpool jets.
Verify that the pump starts and operates without excessive noise or vibration.
Verify that water is circulating and flowing from each jet.
Adjust each jet for optimum flow. Turn the trim ring clockwise to decrease the flow, and
counterclockwise to increase the flow.
Press the air switch a second time to turn off the whirlpool.
Drain the whirlpool.
16. Install the Apron Access Panel
IMPORTANT! Risk of product damage. Ensure that the tabs are aligned before pressing the apron panel
into place. Improper alignment can damage the clips.
Ensure that the apron area is free from obstructions.
Align the center clip of the access panel with the center slot of the apron frame.
Press the center clip until the apron panel snaps into place.
Slide the apron panel up under the apron frame until the two top clips engage and the apron panel
aligns with the remaining clip positions.
When positioned, press on each of the remaining clip locations to engage the snap-in clips.
Fill with water at least 2" (51 mm)
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 switch to turn the
whirlpool on or off.
Sterling 19 1016902-2-F

Troubleshooting
This troubleshooting guide is for general aid only. An Authorized Service Representative or qualified
electrician should correct all electrical problems. For warranty service, contact your dealer or wholesale
distributor.
Symptoms Probable Causes Recommended Action
1. Whirlpool does not
start/stop. A. No power to the pump motor. A. Set/Reset the GFCI breaker. Check the wiring.
B. Air actuator does not work. B. Replace air actuator. Check air tube
between air actuator and pump.
Replace if necessary.
C. Motor/pump does not work. C. Rebuild or replace motor/pump.
2. Motor starts, but all jets
are not functioning. A. Jet is closed. A. Rotate jet trim ring counterclockwise to open.
B. Jet is blocked. B. Remove the blockage.
3. Whirlpool stops
automatically. A. GFCI trips. A. Identify source of fault, and correct.
B. Suction blocked. B. Remove obstruction.
C. Jets are blocked. C. Remove blockage.
D. Motor overheated and
protection device activated. D. Check for blockage at motor vents. Remove blockage and allow motor
to cool.
4. Noisy operation. A. Pump banding straps have not
been cut. A. Cut pump banding straps with a pair of tin snips.
5. Leakage is detected under
the whirlpool. A. Piping leaks. A. Repair any piping leaks.
B. Inadequate sealant application. B. Apply clear 100% silicone sealant
as required.
6. Mold or mildew detected
(for units with wall
surrounds).
A. Blocked channel drainage. A. Use a sharp wooden or plastic
object to scrape any buildup from
the seam. Increase the frequency of
cleaning.
7. Water damage at finished
walls. A. Seam at finished wall not sealed. A. Seal the seam with clear 100% silicone sealant, following the
manufacturer’s instructions.
1016902-2-F 20 Sterling