Kohler K-1630 User manual

Installation Guide
Bath/Shower Whirlpool Module
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”
K-1630 K-1635
1015417-2-C

Important Information
WARNING: When using electrical products, basic precautions should always be followed, including
the following:
DANGER: Risk of electric shock. Connect only to a circuit protected by a Ground-Fault
Circuit-Interrupter (GFCI).
Building materials and wiring should be routed away from the pump body and other heat-producing
components of the unit.
Install to permit access for servicing.
Grounding is required. The unit should be installed by a qualified service representative, and grounded.
WARNING: Risk of electric shock. A licensed electrician should make all electrical connections.
WARNING: Risk of electric shock. Disconnect power before servicing.
WARNING: Risk of injury or property damage. Please read all instructions thoroughly before
beginning installation, including the following requirements.
NOTICE: Follow all local plumbing and electrical codes.
Product Information
Electrical Requirements
The installation must have a Class A Ground-Fault Circuit-Interrupter (GFCI). The GFCI protects against
line-to-ground shock hazard. Use a 120 V, 15 A, 60 Hz dedicated service for the whirlpool.
″H″models require a separate 120 V, 15 A, 60 Hz dedicated service for the in-line heater.
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.
Product Notices
WARNING: Unauthorized modification may cause unsafe operation and poor performance of the
whirlpool. Do not relocate the whirlpool pump, or make other modifications to the whirlpool system,
as this could adversely affect the performance and safe operation of the whirlpool. Kohler Co. shall not
be liable under its warranty or otherwise for personal injury or damage caused by any such
unauthorized modification.
Factory-Assembled Features
Factory installed components include pump with power supply cord and air switch transmitter. No
installation is needed.
″H″models are also supplied with a factory assembled, in-line heater.
An optional timer kit is available for this product.
The whirlpool pump and piping are factory-assembled.
Connections and Service Access
Before installation, ensure proper access to the final connections.
1015417-2-C 2 Kohler Co.

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
information packed with the whirlpool.
Table of Contents
Important Information .............................................................. 2
Product Information ............................................................... 2
Electrical Requirements .......................................................... 2
Product Notices ................................................................ 2
Factory-Assembled 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 Whirlpool ............................................................. 5
Secure the Module to the Stud Framing ................................................ 6
Install the Plumbing ............................................................... 6
Make Electrical Connections ......................................................... 7
Pump Wiring .................................................................. 7
In-Line Heater Wiring ............................................................ 7
Test Run the Whirlpool ............................................................. 7
Complete the Finished Wall ......................................................... 9
Clean-Up After Installation ......................................................... 10
Confirm Proper Operation .......................................................... 10
Fill the Whirlpool .............................................................. 10
Operating Sequence ........................................................... 10
Troubleshooting Procedure ......................................................... 11
Remove the Factory Installed Jets ................................................. 11
Reinstall the Jets .............................................................. 11
Troubleshooting Guide .......................................................... 11
Kohler Co. 3 1015417-2-C

Thank You For Choosing Kohler Company
We appreciate your commitment to Kohler quality. Please take a few minutes to review this manual before
you start your installation. If you encounter any installation or performance problems, please don’t hesitate
to contact us. Our phone numbers and website are listed on the back cover. Thanks again for choosing
Kohler Company.
Tools and Materials
Before You Begin
CAUTION: Risk of product damage. Do not lift the whirlpool by the piping or pump, or use the
piping or pump for structural support of the whirlpool.
We recommend this whirlpool for alcove 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.
Provide sufficient clearance to move the module into the construction area.
Avoid flexing the side walls to prevent damage to the module.
Insulate all exterior walls before installation.
When fire-rated wall is specified, the stud opening dimensions are to the inside of the wallboard.
If the module will be installed adjacent to vertical ducts or chases, surround the unit with fire-rated
gypsum wallboard.
The basin area requires no additional support when the subfloor is level and square with respect to
the stud framing. Consider using shims for additional support if the subfloor is uneven.
Refer to the instructions included with accessories and shower doors before beginning this
installation.
Provide access to all plumbing connections. This is a one-piece module, and you cannot make the
drain and overflow connections by reaching over the end of the module.
To enhance the finished appearance of the tile-wall module designs, pay special attention to
placement of the exposed plumbing fittings. Position the valving and shower fittings where they
will complement the tile-wall appearance of the module.
Sealant Pencil
Level
Pipe Wrench Drill
Tin Snips
Plus:
• Conventional woodworking tools
and materials
• Drop Cloth
• Hole saws
• #6 Large-head galvanized nails
• 2x4's
• Screws or lag bolts
Tape
Measure
Safety
Glasses
1015417-2-C 4 Kohler Co.

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 module should be installed in an alcove installation. Construct 2x4 stud framing designed for
your particular installation. Construct a frame in accordance with the roughing-in information
packed with the whirlpool. Make sure the headers are level and square. Refer to instructions
included with your shower door and accessories before beginning this installation, and add any
additional bridging or support required.
If necessary, leave one of the framing side walls loose until you move the module into position.
Then line the side wall up with the module, and secure the side wall permanently in place to the
stud framing.
Position the plumbing according to the roughing-in information packed. Cap the supplies, and
check for leaks.
2. Prepare the Whirlpool
Install the drain to the whirlpool according to the drain manufacturer’s instructions. Do not connect
the trap at this time.
NOTE: To enhance the finished appearance of the tile-wall module designs, pay special attention to
placement of the exposed plumbing fittings. Position the valving and shower fittings where they will
complement the tile-wall appearance of the module.
Position a clean drop cloth or similar material in the bottom of the whirlpool. Be careful not to
scratch the surface of the whirlpool.
Lay out and mark the location of the mixing valve, shower, and bath spout holes on the back
surface of the module wall. Drill 1/4″pilot holes at the marked locations.
From the inside of the module (finished surface), use a hole saw of the recommended diameter to
carefully drill the fitting holes. Immediately clean the module to reduce the risk of surface damage.
Construct 2x4 stud
framing according to
the roughing-in
information.
If necessary, leave
one of the framing
side walls loose
until you move the
module into
position.
Position
the rough
plumbing.
Verify that the subfloor offers adequate
support, and is flat and level.
Kohler Co. 5 1015417-2-C

3. Secure the Module to the Stud Framing
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.
With help, carefully lift the module into position.
Insert the drain tailpiece into the trap. Make sure the whirlpool is level and resting on all support
blocks.
Plumb and level the module along the nailing-in flanges, and use shims to level the module rim. Do
not support the module by the rim.
Place shims under the module body to add support when module is in use.
Drill small pilot holes 8″(20.3 cm) apart through the vertical nailing-in flanges along the front of the
module. Then drill small pilot holes through the horizontal nailing-in flange at each side and back
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.
For metal stud construction, drill the fastener holes through the nailing-in flange and the metal
studs, and secure with sheet metal screws.
Use #6 large-head galvanized nails to secure the nailing-in flange to the studs.
4. 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.
Nail 1/4" (6 mm) thick furring strips
to shim out to the edge of the
nailing-in flange. Drill a small hole through the
back nailing-in flange at each
stud.
Place shims under the whirlpool
body to provide support when the
whirlpool is in use.
Drill small holes through the side
nailing-in flange 8" (20.3 cm) apart.
Use #6 large-head galvanized nails to secure
the side nailing-in flange to the studs.
Stud
Nailing-In Flange
1015417-2-C 6 Kohler Co.

5. Make Electrical Connections
WARNING: Risk of electric shock. To reduce the risk of electrical shock, connect the pump and in-line
heater (if heater option included) to properly grounded, grounding-type receptacles protected by
Ground-Fault Circuit-Interrupters (GFCI’s). Do not remove the plugs’ grounding pins. Do not use
grounding adapters.
Pump Wiring
NOTE: The whirlpool model number is printed on a label near the whirlpool pump. This label also
identifies the electrical rating of the whirlpool.
Your Kohler whirlpool bath is equipped with a cord and plug. All wiring of the pump and control
has been completed at the factory. A licensed electrician must install a GFCI-protected, 120 V, 15 A,
grounded outlet. No other load should be on this circuit. Locate the outlet behind the whirlpool,
and within 24″(61 cm) of the pump.
Plug the pump into this outlet.
NOTE: Make sure the air actuator tubing is securely attached to the pump, and is not kinked or damaged.
If a K-1639 Timer Kit will be used, install it now according to the instructions packed.
In-Line Heater Wiring
″H″Models: The in-line 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 in-line heater into this outlet.
6. Test Run the Whirlpool
Check all electrical connections, and make sure the electrical power to the whirlpool and in-line
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.
Install a GFCI-protected 120 V, 15 A grounded outlet.
Install a second GFCI-protected outlet for "H" models
for the in-line heater.
Plug pump and
in-line heater into
these outlets.
Make sure the air actuator tubing is
securely attached to the pump.
Bond in accordance with applicable codes.
Connect here.
Optional In-Line Heater
(models may vary)
either T-style (shown) or
water intake (not shown)
Kohler Co. 7 1015417-2-C

Test Run the Whirlpool (cont.)
For additional information on whirlpool operation, refer to ″Confirm Proper Operation″.
1015417-2-C 8 Kohler Co.

7. Complete the Finished Wall
If you have not already done so, carefully remove the protective tape from the whirlpool rim.
Apply a continuous bead of silicone sealant to the nailing-in flanges. Install water-resistant wall
material so the paperbound edge is at least 1/4″(6 mm) above the finished, concave surface of the
whirlpool.
Tape and mud the water-resistant wall material. Install the finished wall material.
Install the mixing valve, shower, and spout trim according to the instructions packed with the trim.
Install any extra grab bars or towel bars to the bridging previously installed. Follow the accessory
manufacturer’s instructions.
Install the shower door according to the manufacturer’s instructions.
Concave Surface
Stud
Apply a continuous
bead of silicone sealant
to the nailing-in flanges
Install water-resistant wall
material so the paperbound
edge is at least 1/4" (6 mm)
above the finished, concave
surface of the whirlpool
Kohler Co. 9 1015417-2-C

8. 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.
9. Confirm Proper Operation
Fill the Whirlpool
NOTE: Please read these steps carefully before you operate your whirlpool.
Position the jet nozzles so they face down toward the basin. Turn the jet trim rings fully
counterclockwise.
Fill the whirlpool to a water level at least 2″(5.1 cm) above the top of the highest jet.
NOTE: The water temperature in the whirlpool should not exceed 104° F (40° C).
Operating Sequence
Press the air actuator to turn on the whirlpool jets.
Adjust each jet for optimum air/water mixture. Turn the trim ring clockwise to reduce the air flow,
and counterclockwise to increase the air flow.
If equipped with an in-line 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.
NOTE: The optional K-1639 Timer Kit automatically stops the whirlpool after approximately 20 minutes of
operation.
Fill with water 2" (5 cm)
above the highest jet
Turn the jet trim
ring clockwise to
decrease the flow Position the jet
nozzles to direct
the water flow as
desired
Turn the jet trim ring
counterclockwise to
increase the flow
Press the air actuator to turn on and
off the whirlpool
1015417-2-C 10 Kohler Co.