Kohler Maestro K-842-V-AB User manual

R
MaestroWhirlpool Baths:
K-842-V-AB
K-842-JA-AA K-845-V-AB K-845-JA-AA
111835-CA (1093) Copyright E1993 Kohler Co.

Kohler Co., Kohler WI
111835-CA (1093) 2
IMPORTANT SAFETY INSTRUCTIONS
ATTENTION INSTALLER: INSTRUCTIONS PERTAINING TO RISK OF FIRE, ELECTRIC
SHOCK OR INJURY TO PERSONS
READ AND FOLLOW ALL INSTRUCTIONS
WARNING: When using this unit, always follow basic precautions, including the following:
DANGER: RISK OF ELECTRICAL SHOCK.
The installation must have Class A
Ground-Fault Circuit-Interrupters (GFCI) for
the whirlpool system.
This will provide additional protection against
line-to-ground shock hazard.
Such a GFCI should be provided by the installer and
should be tested on a routine basis.
TotesttheGFCI,pressthetestbutton.The GFCIshould
interruptpower.Presstheresetbutton.Powershouldbe
restored.
If the GFCI fails to operate in this manner, there is a
ground current flowing or the GFCI is defective. The
possibility of an electric shock may exist. DO NOT use
this unit. Disconnect the unit and have the problem
corrected by a qualified licensed electrician.
For -J1 and -JA models only: Agreencoloredterminal
(or a wire connector marked “G”, “GR”, “GROUND”, or
“Grounding”) is provided within the terminal
compartment. To reduce the risk of electric shock,
connect this terminal or connector to the grounding
terminal of your electric service or supply panel with a
conductor equivalent in size to the circuit conductors
supplying this equipment.
All models: A pressure wire connector is provided on
the exterior of the pump or control box within this unit to
permit connection of a No. 8 AWG (8.4 mm2) solid
copperbondingconductorbetweenthisunitandallother
electricalequipmentandexposedmetalinthevicinity,as
needed to comply with local requirements.
DO NOT operate this unit without the guard on the
suction fitting.
Never drop or insert any object into any opening.
Use this unit only for its intended use as denoted in this
manual. DO NOT use attachments not recommended
by the Kohler Co.
DANGER: To reduce the risk of injury, do not
permit children to use this unit unless they are
closely supervised at all times.
SAVE THESE INSTRUCTIONS

3111835-CA (1093)
Kohler Co., Kohler WI
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS 2. . . . . . . .
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROUGHING-IN: K-842-V-AB, K-845-V-AB,
K-842-JA-AA, K-842-JA-AA 4. . . . . . . . . . . . . . . . . . .
Ordering Information 4. . . . . . . . . . . . . . . . . . . . . . .
Required Electrical Service 4. . . . . . . . . . . . . . . . . .
Product Information 4. . . . . . . . . . . . . . . . . . . . . . . .
Installation Notes 4. . . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT NOTICES 5. . . . . . . . . . . . . . . . . . . . . . . . .
Installer Hazard Notification 5. . . . . . . . . . . . . . . . .
Factory-Assembled Features 5. . . . . . . . . . . . . . . .
PRODUCT REQUIREMENTS 6. . . . . . . . . . . . . . . . .
Summary of Key Requirements 6. . . . . . . . . . . . . .
Plumbing Specifications 6. . . . . . . . . . . . . . . . . . . . .
Product Inspection 6. . . . . . . . . . . . . . . . . . . . . . . . .
Connections and Service Access 6. . . . . . . . . . . . .
Electrical Requirements 6. . . . . . . . . . . . . . . . . . . . .
INSTALLATION REQUIREMENTS 7. . . . . . . . . . . . .
Tools Required 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials Required 7. . . . . . . . . . . . . . . . . . . . . . . . .
Clearance Requirements 7. . . . . . . . . . . . . . . . . . . .
New or Replacement Installation Requirements 7
SITE REQUIREMENTS 8. . . . . . . . . . . . . . . . . . . . . . .
Old Bath Removal 8. . . . . . . . . . . . . . . . . . . . . . . . . .
Subfloor Preparation 8. . . . . . . . . . . . . . . . . . . . . . . .
Stud Pocket Preparation 8. . . . . . . . . . . . . . . . . . . .
Plumbing Preparation 9. . . . . . . . . . . . . . . . . . . . . . .
BEFORE INSTALLING UNIT 9. . . . . . . . . . . . . . . . . .
Tiling-In Bead Installation 9. . . . . . . . . . . . . . . . . . . .
Partially Install Bath Drain 9. . . . . . . . . . . . . . . . . . .
Protect Bath Unit 9. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALL WHIRLPOOL 10. . . . . . . . . . . . . . . . . . . . . . .
Whirlpool Set-In 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Plumbing 10. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALL GRIP RAILS 10. . . . . . . . . . . . . . . . . . . . . . . .
FIELD WIRE ELECTRONICS 11. . . . . . . . . . . . . . . . . .
Identify Electrical Requirements 11. . . . . . . . . . . . . .
Wiring Information - 120 V, 60 Hz 11. . . . . . . . . . . . .
Field Wiring Control Box Compartment -
230 V, 50 Hz 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect Control Box - 230 V, 50 Hz 12. . . . . . . . . .
WATER TEST WHIRLPOOL & ELECTRONICS 12. .
COMPLETE FINISH WALL 12. . . . . . . . . . . . . . . . . . . .
COMPLETE INSTALLATION 13. . . . . . . . . . . . . . . . . . .
Install Handles and Spout 13. . . . . . . . . . . . . . . . . . .
Install Whirlpool Trim Kit 13. . . . . . . . . . . . . . . . . . . .
CLEAN-UP AFTER INSTALLATION 13. . . . . . . . . . . .
CONFIRM PROPER OPERATION 14. . . . . . . . . . . . .
Start-Up Whirlpool 14. . . . . . . . . . . . . . . . . . . . . . . . .
Operating Sequence 14. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshoot Whirlpool System 15. . . . . . . . . . . . . .
INTRODUCTION
Please read these instructions carefully to familiarize
yourself with the required tools, materials, and
installation sequences. Follow the sections that pertain
toyourparticularinstallation. Thiswillaidyouinavoiding
the unnecessary expense associated with improper
installation. In addition to proper installation, read all
operating and safety instructions.
The variety of installations possible with this whirlpool
may require framing procedures other than those
described in this manual.
All information in this manual is based on the latest
product information available at the time of publication.
Kohler Co. reserves the right to make changes in
product characteristics, packaging, or availability at any
time without notice.
Identify and record below the model and serial number (found at the pump end of the whirlpool):
Model No. Serial No. Date of Manufacture

1.75>132
PUMP
1-1/2” I.P.S. THR’D
PUMP/CONTROL ACCESS
1-1/2” O.D.
3/4”
18-1/4”
1/4”
2-7/8”
3”
9-1/4”
16”
32”
2-1/4”
3-1/4”
66”
FIELD WIRING
COMPARTMENT
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111835-CA (1093) Kohler Co., Kohler WI
1. ROUGHING-IN: K-842-V-AB, K-845-V-AB, K-842-JA-AA, K-845-JA-AA
A. ORDERING INFORMATION
Factory installed components include pump with integral
timer, and air switch transmitter.
Applicable product:
With grip rails (K-9621) K-842 shown
Without grip rails K-845 not shown
Accessories/hardware:
Jet trim kit K-9695 required
Grip rails K-9621 required for
K-842
Drain K-7161-AF recom-
mended
Vinyl tiling-in bead* K-1179 optional
*Use K-1179 vinyl bead when wall material contacts
any top surface of bath.
*K-9621 are sold separately and are required accesso-
ries.
B. REQUIRED ELECTRICAL SERVICE
Dedicated circuits required, protected with Class A
Ground-Fault Circuit-Interrupter (GFCI):
Pump/control 120 V., 15 A, 60 Hz
or 230 V., 15 A, 50 Hz
C. PRODUCT INFORMATION
Fixture: basin area top area weight
Bathing well 46-1/2” x
21” 57” x 25” 410 lbs.
water depth capacity
To overflow 13” 55 gal.
Pump, 1-speed: hp V Hz A
60 Hz 3/4 120 60 10
50 Hz 3/4 230 50 5.5
D. INSTALLATION NOTES
Refertoinstallationinstructionsincludedwithfixturebefore
beginning installation.
ROUGHING-IN NOTES
Fixture dimensions are nominal and conform to toler-
ances in ANSI Standard A112.19.1
No change in measurements if connected with drain
illustrated.
Cut-out 64-1/2” x 30-1/2”
Minimum access:
Pump/control box 20” W x 15” H panel required

5111835-CA (1093)
Kohler Co., Kohler WI
2. PRODUCT NOTICES
A. INSTALLER HAZARD NOTIFICATION
DANGER: Risk of fire, electric shock, or injury
to persons. Readimportantsafetyinstructionson
inside front cover of these instructions.
WARNING: Risk of electrical shock.A licensed
electrician should make all electrical connections.
WARNING: Risk of electrical shock. Connect
only to a circuit protected by a Ground-Fault
Circuit-Interrupter (GFCI).
WARNING: Risk of electrical shock.
Disconnect power before servicing.
WARNING: Risk of injury or property damage.
Please read all instructions thoroughly before
beginning installation, including the following
Product Requirements.
NOTICE: Follow all local plumbing and electrical
codes.
B.FACTORY-ASSEMBLED FEATURES
Factoryinstalledcomponentsincludepumpwithintegral
timer and air switch transmitter. No installation is
needed.
The whirlpool pump and piping are factory-assembled.
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
otherwiseforpersonalinjuryordamagecausedby
any such unauthorized modification.

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111835-CA (1093) Kohler Co., Kohler WI
3. PRODUCT REQUIREMENTS
A. SUMMARY OF KEY REQUIREMENTS
SInstall unit to level subfloor.
SProvide properly dimensioned framing.
SBath can be installed as a corner, recess or sunk-
en installation.
B. PLUMBING SPECIFICATIONS
If using a rim mounted bath faucet, flexible connections
between the valves and spoutmay be required. Confirm
adequate mounting and connection space of specified
faucet for your installation.
Confirm adequate support for faucet; large faucets that
maybeinadvertentlyusedasameansofsupportarenot
appropriate or safe for this installation.
C. PRODUCT INSPECTION
Carefully uncrate and inspect your product for damage.
Leave all materials in carton during construction to
prevent damage.
NOTICE: Make sure both connections to the
whirlpool pump are securely tightened.
D. CONNECTIONS AND SERVICE ACCESS
Before installation, ensure proper access to the final
connections.
NOTICE: Provide unrestricted service access to
the pump. An access panel 20” W x 15” H minimum
must be constructed to allow for sufficient clearance for
servicing the pump or controls. The access panel must
be located at the pump end of the whirlpool, through an
adjoining wall.
E. ELECTRICAL REQUIREMENTS
K-842-V-AB, K-845-V-AB: The installation must have
a Class A Ground-Fault Circuit-Interrupter (GFCI). The
GFCI protectsagainst line-to-groundshockhazard.Use
a 120 V, 15 A, 60 Hz separate service for thewhirlpool.
Provide a separate equipment grounding conductor for
theinsidegroundinglug.Groundmustnotbeconnected
to any current-carrying conductor except at the main
service breaker box.
K-842-JA-AA, K-845-JA-AA: The installation must
haveanEarthLeakageCircuitBreaker (ELCB).Thiswill
provide additional protection against line-to-ground
shock hazard. A 230 V, 50 Hz separate circuit that
provides15 A of continuous service is required.

7111835-CA (1093)
Kohler Co., Kohler WI
4. INSTALLATION REQUIREMENTS
A. TOOLS REQUIRED
SConventional woodworking tools
SArc pliers or 14” pipe wrench
SRule
SLevel
SSafety shoes
SSafety glasses
SSquare
SScrewdriver
SPliers
SUtility knife
B. MATERIALS REQUIRED
SPlumbers putty
SWater-resistant sealer
SWall coverings, as necessary
SRTV silicone sealant
C. CLEARANCE REQUIREMENTS
Check roughing-in and room dimensions in order to
provide adequate available space for the bath unit.
D. NEW OR REPLACEMENT INSTALLATION
REQUIREMENTS
This bath unit can be installed in new or existing
bathrooms.
For new installations: Position plumbing according to
roughing-indimensionslocatedonpage4.Capsupplies
and check for leaks.
For replacement installations: Remove old bath,
remove old wall material and remove old floor covering
from area. Remove old plumbing which does not
conform to roughing-in requirements.

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111835-CA (1093) Kohler Co., Kohler WI
5. SITE REQUIREMENTS
A. OLD BATH REMOVAL
Disconnect the drain at the trap. Remove old wall
material. Slip boards under old bath feet to protect
floor and slide old bath out of recess as illustrated.
Floor
Protection
Boards
Old Bath
B. SUBFLOOR PREPARATION
Check flooring under the bath and repair if necessary.
Make sure that the subfloor is level. Seal subfloor to
reduce the risk of water damage.
C. STUD POCKET PREPARATION
Construct a recess designed for your particular
installation. Framing is of 2 x 4 construction. When
constructing framing, allow for thickness of sub and
finished wall materials.
If an apron wall without a ledge is desired, the finished
apron wall surface must be 1/32” under the bath rim.
Bath can be installed as a corner, recess or sunken
installation. Possible studding arrangements are
illustrated in 1. through 3. below; modifications may be
needed for other types of construction.
1. Corner Installation: Suggested stud construction
is illustrated.

9111835-CA (1093)
Kohler Co., Kohler WI
2. Sunken Installation: For sunken installation,
refer to Roughing-In notes located in Roughing-In
sectionbeginningonpage4forcut-outdetail.Make
sure the bath is supportedby the supportingblocks
at the bottom of the bath.
3. Recessed Installation: Suggested stud
construction is illustrated.
D. PLUMBING PREPARATION
Position plumbing according to roughing-in dimensions.
Cap supplies and check for leaks.
6. BEFORE INSTALLING UNIT
A. TILING-IN BEAD INSTALLATION
Before setting bath, an optional tiling-in bead is
recommendedtobeappliedtowhateversideofthebath
contacts the wall. Refer to Ordering Information located
in Roughing-In section beginning on page 4. This bead
prevents water from seeping between the bath and the
wall. Install this bead now. Refer to Installation
Instructions packed with the tiling-in bead.
B. PARTIALLY INSTALLBATH DRAIN
Install drain on bath/whirlpool according to
manufacturer’s instructions.
C. PROTECT BATH UNIT
Place a drop cloth or similar material in bath/whirlpool
bottom. Be careful not to scratch product.

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111835-CA (1093) Kohler Co., Kohler WI
7. INSTALL WHIRLPOOL
A. WHIRLPOOL SET-IN
CAUTION: Risk of product damage.Donotuse
the piping or pump for structural support or
positioning.
Slide new bath into position. Insert tailpiece into trap.
Shimunderwhirlpoolfeetasnecessarywithmetalshims
to level. Bath must be level and resting on all four feet.
Check for level along the top of the side of the whirlpool
and across the drain end. Whirlpool may have to be
moved in and out of recess area untilshimmed properly
if feet are not accessible from back or side.
Metal Shims
Metal Shim
B. INSTALL PLUMBING
CAUTION: Risk of damage to whirlpool
bottom and subfloor. Ensure watertight seal on
bath drain connections.
1. When whirlpool is securely positioned, connect
drain into trap. An access panel will simplify future
maintenance.
Connect Here
2. Install the faucet valving and spout tee. If faucets
are deck-mounted, the deck must be finished
beforehandletrimandspoutcanbeinstalled.Open
hot and cold valves and check all supply
connections for leaks.
3. Run water in whirlpool and check drain connection
for leaks.
8. INSTALL GRIP RAILS
RefertoInstallationInstructions packed with theK-9621
grip rail kit when installing grip rails.

11 111835-CA (1093)
Kohler Co., Kohler WI
9. FIELD WIRE ELECTRONICS
A. IDENTIFY ELECTRICAL REQUIREMENTS
The model number is printed on a plate at the pump end
of the module.
The model number identifies electrical rating. Electrical
connections for each model vary.
SK-842-V-AB, K-845-V-AB: 60 Hz
(Follow Step B. below.)
SK-842-JA-AA, K-845-JA-AA: 50 Hz
(Follow Steps C. and D. below.)
See Electrical Requirements section on page 6 of
Product Requirements.
B. WIRING INFORMATION - 120 V, 60HZ
(EXCLUDING -J1 MODELS)
WARNING: Risk of electrical shock. Toreduce
theriskofelectricshock,connectonlytoaproperly
grounded, grounding-type receptacle, protected
by a Ground-Fault Circuit-Interrupter (GFCI). Do
not remove the plug’s grounding pin. Do not usea
grounding adapter.
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 Volt, 15 Amp, grounded
outlet. Your whirlpool may then be plugged into this
outlet. No otherload shouldbe onthis circuit.Locate the
outlet within reach of the 36” cord.
C. FIELD WIRING CONTROL BOX
COMPARTMENT - 230 V, 50 HZ
WARNING: Risk of electrical shock. Makesure
the power has been disconnected before
performing the following procedures. Refer to
Important Safety Instructions located on page 2.
CAUTION: Riskofelectricalshock.Allservices
must have an Earth Leakage Circuit Breaker
(ELCB) which will provide additional protection
against line-to-ground shock hazard. A separate
service is required for the whirlpool.
The whirlpool controls and system have been prewired
at the factory. A licensed electrician should make a
routine service connection to the field wiring
compartment of the control box containing blue and
brown wires and earth lug.
* For bonding in accordance with National and Local
Codes.
Field Wiring
Compartment
Bonding
(Earthing) Lug*
Air
Actuator
Air
Actuator
Tube
Pump
Control
Box

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111835-CA (1093) Kohler Co., Kohler WI
D. CONNECT CONTROL BOX - 230 V, 50 HZ
Connect service to the field wiring compartment of the
control box. The 50 Hz model control box contains blue
and brown wires and earth lug.
A 230 V, 15 A, 50 Hz dedicated circuit is required.
Provide an Earth Leakage Circuit Breaker.
Provideaseparateequipmentearthingconductorforthe
inside earth lug. The earthing conductor must not be
connected to any current carrying conductor. Follow
local electrical codes. A 230 V, 15A, 50 Hz separate
circuit is required.
Earth
(Ground) Lug
Earth
(Ground)
Neutral
Earthing Lug (for
bonding in accor-
dance with national
and local codes)
Blue
(Neutral)
Brown
(Phase)
Wire Connectors
Phase (Line)
10. WATER TEST WHIRLPOOL & ELECTRONICS
Check all electrical connections. Make sure both
connections to the pump are securely tightened.
Fill bath to a level at least 2” above the top ofthe highest
jet.
Operate whirlpool for 5 minutes and check all whirlpool
harness (piping) connections for leaks.
For additional information on whirlpool operation, see
Whirlpool Start-Up Instructions on page 14.
11. COMPLETE FINISH WALL
CAUTION: Risk of product damage. Do not
support the weight of the whirlpool by the rim.
Protect whirlpool surface. Make sure the vinyl bead is
attached securely to the sides being built into the wall.
Cover framing and walls with gypsum wallboard.
Tape and mud drywall...seal drywall and joints under
bath rim. Install finished wall material to subwall. Seal
joints between the whirlpool rim and finished wall using
silicone sealant.
Gypsum Wallboard Subwall
Finished Wall Material
Water-Resistant Sealant
2 x 4 Studding
Vinyl Tiling-In Bead
Bath Rim

13 111835-CA (1093)
Kohler Co., Kohler WI
12. COMPLETE INSTALLATION
A. INSTALL HANDLES AND SPOUT
After the deck is finished, attach the handles and spout
to complete faucet installation per manufacturer’s
instructions.
B. INSTALL WHIRLPOOL TRIM KIT
Refer to Installation Instructions packed with the trim kit
when installing jet trim or suction trim.
13. CLEAN-UP AFTER INSTALLATION
When cleaning up after installation, do not use
abrasive cleaners as they may scratch and dull the
module surface. Use warm water and one of the liquid
detergents to clean the surface.
Stubborn stains, paint, or tar can be removed with
turpentine or paint thinner. Do not allow cleaners
containing petroleum distillates to remain in
contact with whirlpool surfaces for long periods of
time. Plaster can be removed by scraping with a wood
edge. Donotuse metal scrapers,wirebrushes,or other
metal tools. One of the powder-type detergents may be
used on a damp cloth to provide mild abrasive action to
the residual plaster.

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111835-CA (1093) Kohler Co., Kohler WI
14. CONFIRM PROPER OPERATION
A. START-UP WHIRLPOOL
Refer to Important Safety Instructions on page 2
before operating this whirlpool.
Please perform the following so that the owner may
safely receive the benefits of whirlpool bathing.
1. Rotate jets so they are facing down toward basin.
2. Fill the whirlpool bath to a water level at least 2”
above the top of the highest jet.
Water temperature in the whirlpool should not
exceed 104_F (40_C).
Bath
Wall 2” Minimum
Water Line
Jet Trim
B. OPERATING SEQUENCE
Refer to chart for proper operating sequence.
1. Turn on the whirlpool jets. Adjust each jet for
optimum air/water mixture.
2. A built-in timer automatically stops the motor after
20 minutes of operation. Reduce
Air Add
Air
TO METHOD OBSERVE
Turn on whirl-
pool massage.
Add air to whirl-
pool action, rotate
flange counter-
clockwise. To
reduce air, turn
clockwise.
Shut off whirlpool.
Restart whirlpool
after 20 minute
cycle is com-
plete.

15 111835-CA (1093)
Kohler Co., Kohler WI
C. TROUBLESHOOT WHIRLPOOL SYSTEM
Thistroubleshootingguideisforgeneralaidonly. AKohlerAuthorizedServiceRepresentativeoraqualifiedelectrician
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 pump/power module. A. Set/Reset GFCI/ELCB breaker; check wiring to power module.
B. Air actuator tubing disconnected,
loose, kinked, plugged or damaged. B. Connect, straighten, clean or replace tubing.
C. Faulty air actuator. C. Replace air actuator.
D. Faulty motor/pump assembly. D. Rebuild or replace motor and pump
assembly.
2. Motor starts, all jets
are not functioning
A. Jet is closed. A. Rotate jets counterclockwise to open.
are not functioning. B. Trim kit installed incorrectly. B. Reinstall trim kit, checking for damage
to O-Ring.
C. Jets are blocked. C. Remove blockage.
3. Motor turns, water
is pumping, but A. No aspiration at jets. A. Rotate jets counterclockwise.
is um ing, but
there is no air
injection. B. Jet O-Rings are missing. B. Replace jet O-Rings.
4. Whirlpool stops
automatically
A. GFCI/ELCB trips. A. Identify source of fault and correct.
automatically
before 18 minutes. B. Suction blocked. B. Remove obstruction.
before 18 minutes
.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. Check for suction blockage.
Remove blockage and allow motor to
cool. Check for jet blockage. Remove
blockage and allow motor to cool.
5. Whirlpool does not
automatically sto
pA. Faulty timer mechanism. A. Replace timer board. au
t
oma
ti
ca
ll
y s
t
op
after 22 minutes. B. Wiring error. B. Refer to dealer.

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111835-CA (1093) Kohler Co., Kohler WI