Kohler BodySpa K-1000 User manual

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116290-2-AB 2001 Kohler Co.
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BODYSPA
PERSONAL HYDRO-MASSAGE SYSTEM
10-JET ALCOVE
K-1000, K-1015/16, K-5161-L
IMPORTANT! READ THIS BEFORE YOU BEGIN
ThisBodySpaoperatesat flow rates upto80 gallons per
minute. To achieve a watertight installation, it is critical
that you follow all the installation instructions carefully.
Pay particular attention to leveling and sealing details to
obtain a satisfactory installation.
IMPORTANT INFORMATION
WARNING: When using electrical products,
basic precautions should always be followed,
including the following:
DANGER: Risk of electrical shock.Connectonly
to a circuit protected by a Ground-Fault
Circuit-Interrupter (GFCI).
Install to permit access for servicing.
Grounding is required. The unit should be installed and
grounded by a qualified service representative.
Buildingmaterials and wiring should be routed away from
the pump body and other heat-producing components of
the unit.
TABLE OF CONTENTS
PRODUCT NOTICES 2. . . . . . . . . . . . . . . . . . . . . . . . .
PRODUCT REQUIREMENTS 2. . . . . . . . . . . . . . . . . .
SITE REQUIREMENTS 3. . . . . . . . . . . . . . . . . . . . . . . .
BEFORE INSTALLING FOOTBATH 4. . . . . . . . . . . . .
INSTALL THE FOOTBATH 4. . . . . . . . . . . . . . . . . . . . .
BEFORE INSTALLING TOWER 7. . . . . . . . . . . . . . . . .
ELECTRICAL CONNECTIONS 9. . . . . . . . . . . . . . . . .
INSPECT CONNECTIONS 9. . . . . . . . . . . . . . . . . . . . .
DOOR ENCLOSURE PREPARATION 10. . . . . . . . . . .
INSTALL THE ENCLOSURE 10. . . . . . . . . . . . . . . . . . .
INSTALL THE TOWER 19. . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE INSTALLATION 21. . . . . . . . . . . . . . . . . . .
INSTALL THE SEAT 23. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TEST FOOTBATH AND TOWER 23. . . . . . . .
CLEAN-UP AFTER INSTALLATION 23. . . . . . . . . . . . .
CONFIRM PROPER OPERATION 24. . . . . . . . . . . . . .

116290-2-AB 2Kohler Co., Kohler WI U.S.A.
1. PRODUCT NOTICES
A. INSTALLER HAZARD NOTIFICATION
WARNING: Risk of electrical shock. A licensed
electrician should make all electrical connections.
WARNING:Riskofelectricalshock.Connectonly
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
Factory installed components include pump with integral
heater, control, and power supply cord.
The pump and piping are factory-assembled.
C. PRODUCT MODIFICATIONS
All information in this manual is based upon 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.
WARNING: Unauthorized modification may
cause unsafe operation and poor performance
oftheBodySpa. Donotrelocatethepumpormake
other modifications to the BodySpa system, as this
could adversely affect the performance and safe
operation of the unit. Kohler Co. shall not be liable
underitswarrantyorotherwiseforpersonalinjuryor
damage caused by any such unauthorized
modification.
The BodySpa is not designed for steam applications, and
may not perform satisfactorily as a steam unit.
2. PRODUCT REQUIREMENTS
A. PRODUCT INSPECTION
The BodySpa door enclosure, footbath, and tower are
specifically designed for this installation. Before
proceeding with the installation, check the model
numbers of the footbath, tower, and door enclosure. The
door enclosure, tower, and footbath model numbers are
provided in the roughing-in information packed with the
product.
Carefully unpack and inspect the footbath and tower for
damage. Do not unpack the door enclosure until
instructed to do so. Leave all materials in the cartons
during construction to prevent damage.
NOTICE: Make sure the union connection to the
pump inlet is securely tightened.
B. CONNECTIONS AND SERVICEACCESS
Before installation, ensure proper access to the final
connections.
NOTICE: Provide unrestricted service access to the
pump. An access panel must be constructed to allow for
sufficient clearance for servicing the pump or controls.
Theaccesspanelmustbelocatedimmediatelynexttothe
pump. Refer to the roughing-in information packed with
the product and the stud framing preparation on Page 3.

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Kohler Co., Kohler WI U.S.A.
C. 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, 20 A, 60 Hz
dedicated service for the BodySpa.
3. SITE REQUIREMENTS
A. CLEARANCE REQUIREMENTS
Thedistance from therough floortothe finishedceiling or
header must be between 83-1/2” and 84” to provide
adequateclearancewhenassemblingthedoorenclosure
to the footbath. Be sure the ceiling and header are level.
B. STUD POCKET PREPARATION
NOTE: Carefully study the illustration at right before you
begin construction of the stud pocket. Follow the framing
details provided to ensure correct installation.
Use 2x6 framing for the tower wall to provide sufficient
space for the tower mounting frame and wiring, and
minimum2x4framingfortherestofthestudpocket.Make
sure you allow for access to the pump in the event the
BodySpa requires service.
Provide double stud support for the door enclosure wall
jambs. You must secure the door enclosure wall jambs
directly to the studs to obtain proper support and correct
opening dimensions. Expanding wall anchors will not
provide adequate support for the door enclosure
assembly.
You must install these stud supports to be within 3/8”
of plumb for proper door enclosure installation. Maintain
this tolerance to ensure a satisfactory, watertight
installation.
The footbath requires no additional bottom support when
the rough floor is plumb and level with respect to the stud
framing. If the rough floor is not level, shim it as needed.
Verifythatthedistance from the rough floor to the finished
ceiling is between 83-1/2” and 84”.
IMPORTANT: Leave studs exposed. You must secure
thedoorenclosurewalljambsdirectlytothestuds.Under
no circumstances install the finished wall material until
instructed.
If grab bars will be installed, provide backing to the
framing.
83-1/2”
to 84”
15-11/16”
12”
PUMP/
CONTROL
ACCESS
9-3/4”
54”
31-7/8”
16”
DOUBLE STUD
(REQUIRED FOR
ENCLOSURE
INSTALLATION)
PROVIDE
ACCESS
TO DRAIN
10-3/4”
ROUGH FLOOR
DOUBLE STUD
(REQUIRED FOR
ENCLOSURE
INSTALLATION)
2x6 STUDS
C. PLUMBING PREPARATION
Position the plumbing according to the roughing-in
dimensions. Cap the supplies, and check for leaks.

116290-2-AB 4Kohler Co., Kohler WI U.S.A.
4. BEFORE INSTALLING FOOTBATH
Install the drain to the footbath according to the drain
manufacturer’s instructions. When installing the drain
overflowtube andhood, besure toadequately sealalong
the edges of the hood to prevent leakage.
5. INSTALL THE FOOTBATH
A. CONFIRM STUD POCKET ROUGH-IN
The door enclosure is specifically designed for this
footbath. For proper installation, make sure the double
studsforthewalljambsareinpositionbeforeinstallingthe
unit. Proper door enclosure assembly depends upon
installation of the footbath against square and plumb (to
within 3/8”) studding. Verify this before proceeding with
the installation.
B. INSTALL THE FOOTBATH
1. The variable flow valve assembly is attached to the
suctionline ofthe footbathharness forshipping, and
the wires are connected to the pump. Cut the
strapping, and remove the variable flow valve
assembly. Remove and discard the plug on the end
of the pump union. Then temporarily connect the
variable flow valve to the pump by loosely threading
the union nut to the pump discharge union.
2. Set the footbath on the subfloor. Align the trap with
the tailpiece.
3. Position a clean drop cloth in the footbath to prevent
damage.
4. Leveltheunitusingthefootbathrimsurfaces.Donot
use the nailing-in flange to level the unit. The
footbathmustbe level toproperly install andoperate
the door enclosure.
Pump
Variable Flow
Valve Assembly
5. Securely shim under the wood blocks as needed.
Secure the footbath to the studding using the
nailing-inflange and galvanized drywall screws.Drill
and countersink pilot holes halfway up the nailing-in
flange. Drill from the finished side of the nailing-in
flange to prevent chipping of the acrylic.
6. Add furring strips to the stud framing inside the
recess area. This will make the studs even with the
footbath nailing-in flange.
Nailing-In
Flange

116290-2-AB
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Kohler Co., Kohler WI U.S.A.
C. CONSTRUCT THE APRON
NOTE: Kohler Co. recommends this procedure for
constructing a BodySpa apron. Other methods can be
used to obtain an acceptable result.
1. Cut four 3/4” plywood boards to 6” x 34-1/4”.
Measure and cut a 55taper at one end of each
board, and a 75taper at the other end. Both ends
must taper to the same side.
2. Drawapencilmark3”fromthelongsideofoneofthe
boardsat the 75taperend. Draw asecond mark 5”
from the long side, as shown.
3. Use a pencil, string, and nail to carefully draw a
51-1/4”radius(for 1/2” thickfinished wall) acrossthe
full length of the board at the 3” pencil mark. For
different finished wall thickness, adjust this radius
accordingly. Draw a 49-1/4” radius across the 5”
pencil mark.
4. Use a saber saw to cut the plywood along the radius
lines.
5. Use this board as a template to mark and cut the
other three plywood boards.
3”
5”
Measure 3” and 5”
Down From This
Edge
6”
7555
34-1/4”
51-1/4” R.
49-1/4” R.
6. Cut four 3/4” plywood boards to 2” x 6”, with a 50
taper on one end.
7. Cut twelve 2x2 studs 9” long.
8. Assemble the apron frame sections as shown.
9”
3/4” Plywood
3/4” Plywood
2x2 Studs
10-1/2”
50
6”
2”
9. Positiontheapronframesectionsunderthefootbath
rim so the 75tapered ends of the curved sections
touch. Align the apron frame sections so they are
recessed correctly for the finished apron wall
thickness. Make sure the sections are plumb.
10. Secure the apron frame sections to the floor.

116290-2-AB 6Kohler Co., Kohler WI U.S.A.
D. TOWER MOUNTING FRAME PREPARATION
On one of the tower mounting studs, draw a pencil line
exactly2-3/8”upfromtheflatsurfaceoftheseatdeck.You
will use this mark to position the tower mounting frame at
the correct height. Be precise with this measurement. 2-3/8”
E. PUMP BANDING STRAP CUT
NOTICE: This step is necessary to make your Kohler
BodySpa operate more quietly.
Use tin snips to cut the banding strap. When the banding
strap is cut, the pump base and pump will continue to rest
upon the plywood ledge that extends from under the
footbath.
Suction Line
Pump
Subfloor
Banding Strap
Pump Base
Plywood
Ledge
F. INSTALL PLUMBING
CAUTION: Risk of damage to footbath bottom
and subfloor. Ensure a watertight seal on the
footbath drain connections.
When the footbath is securely positioned, connect and
leak test the drain and fittings.
NOTE: An access panel will simplify future
maintenance. Connect Here

116290-2-AB
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Kohler Co., Kohler WI U.S.A.
6. BEFORE INSTALLING TOWER
A. INSTALL THE MOUNTING FRAME
Remove three 3/8” tower bolts from the locations shown,
and carefully lift the tower out of the mounting frame.
Carefullysetthetowerasidewhereitwillnotbedamaged.
Bolts
Bolt
Set the mounting frame between the tower mounting
studs, and line up the bottom metal edge with the pencil
line you drew on one of the studs.
Secure the mounting frame to the tower mounting studs
with ten stainless steel drywall screws provided.
Mounting
Stud
Mounting
Frame
Pencil
Line
Stainless
Steel Drywall
Screw

116290-2-AB 8Kohler Co., Kohler WI U.S.A.
B. INSTALL CABLE USING OUTLET BOX
NOTE: Ifthe desired keypadlocationdoes not permityou
tosecuretheprovidedoutletboxdirectlytoastud,youcan
route the control cable directly through the wall material
without using an outlet box. Proceed to Step C. to install
the keypad without an outlet box.
Plugthecontrolcableintothe right jack of thecontrolbox.
Positionthesuppliedoutletboxinsidetheenclosureatthe
chosen control mounting location so the metal plate (not
shown) will be flush with the finished wall or slightly
recessed when installed. Install the outlet box so the 10’
control cable is within reach of the control box. Do not
stretch or pull on the control cable. Install the outlet box
58” to 60” up from the floor of the footbath.
Secure the outlet box to the nearest stud.
Route the control cable from the control box to the outlet
box,and insert thelooseconnectorintotheknockouthole
in the outlet box. Create a drip loop in the cable.
NOTE: National Electrical Code requires that you
permanently separate the high- and low-voltage cables.
Stud
Outlet Box
SIDE VIEW
Stud
Outlet
Box
Control
Cable
Control Box
58” To 60”
From Floor
Drip Loop
C. INSTALL CABLE WITHOUT OUTLET BOX
Plugthecontrolcableintothe right jack of thecontrolbox.
Route the control cable directly through the large hole in
the center of the metal plate. Temporarily tape together
the control cable and the metal plate. Also tape the two
screws to the metal plate to prevent them from becoming
lost. Create a drip loop in the cable to prevent water from
following the cable down to the control box.
Temporarily secure the control cable and metal plate to
the stud nearest your chosen keypad mounting location.
Position the metal plate 58” to 60” up from the floor of the
footbath.
Leave the control cable and metal plate attached here
untilthefinishedwallisconstructed.Atthattime,themetal
plate will be permanently attached flush to the outside
surface of the finished wall with two screws. The control
cable will then be secured to the metal plate with a cable
tieloopedbetween the large andsmallcenter holes in the
metal plate.
NOTE: National Electrical Code requires that you
permanently separate the high- and low-voltage cables.
Control Cable
Control Box
To Metal Plate
Metal Plate
Control Cable
Drip Loop

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Kohler Co., Kohler WI U.S.A.
D. CONNECT VARIABLE FLOW VALVE
ASSEMBLY TO PUMP
Loosen the variable flow valve assembly by unthreading
theunionnut.Repositionthevariableflowvalveassembly
sotheoutlet union lines upwiththe mounting frame union
nut.Securelyhandtightentheunionnut.Besuretheunion
O-ring is in place. Do not apply sealant to the union.
Handtighten the mounting frame union nut to the variable
flow valve union. Be sure the union O-ring is in place. Do
not apply sealant to the union.
Pump
Mounting
Frame
Union Nut
Mounting
Frame
Variable Flow
Valve Assembly
BACK VIEW
7. ELECTRICAL CONNECTIONS
WARNING: Risk of electrical shock. To reduce
theriskofelectricshock,connectonlytoaproperly
grounded, grounding-type receptacle, protected
by a Ground-Fault Circuit-Interrupter (GFCI). Do
not remove the plug’s grounding pin. Do not use a
grounding adapter.
The Kohler BodySpa 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, 20 A, grounded outlet. The
BodySpa may then be plugged into this outlet. No other
load should be on this circuit. Locate the outlet behind
the BodySpa, and within 24” of the pump.
* For bonding in accordance with national and local
codes.
Bonding
(Earthing)
Lug*
Pump
Plug-in
Cord 20 A
Receptacle
Control Box
8. INSPECT CONNECTIONS
Check all electrical connections.
Openthehotandcoldwatervalves,andcheckallsupply
connections for leaks. Fill the footbath to the overflow,
and check the overflow and drain connections for leaks.

116290-2-AB 10 Kohler Co., Kohler WI U.S.A.
9. DOOR ENCLOSURE PREPARATION
The BodySpa door enclosure is designed to fit only the
BodySpa footbath. Proper door enclosure assembly
depends upon installation of the footbath against square
and plumb studding. The stud supports must be within
3/8” of plumb.
IMPORTANT: Leave studs exposed. The door
enclosure wall jambs must be secured directly to the
double stud wall frame to achieve proper support of the
door enclosure. Expanding wall anchors in a hollow wall
will not provide adequate support for the door enclosure
assembly. Under no circumstances install the finished
wall material until instructed.
NOTE: The door enclosure components are identified
with removable labels. Refer to these labels to correctly
identify and install the enclosure components.
10. INSTALL THE ENCLOSURE
A. INSTALL THE WALL JAMBS
Removethewalljambkitfromthecarton,andremovethe
wall jambs. Leave the wall jamb protective tape in place.
Do not remove any other components from the carton at
this time.
Install one of the wall jambs by setting it against the
footbath locating pin, as shown. The wall jambs are not
interchangeable.
Use a level, and adjust the wall jamb to be exactly plumb.
Secure the wall jamb to the double stud framing and
furring strips with four 2” stainless steel flathead screws
(provided).
Repeat for the other wall jamb. 2” Stainless
Steel Flathead
Screw
Wall
Jamb
Footbath Locating Pin
Level