Kohler Whirlpool Baths User manual

Kohler Whirlpool Baths
2-Speed Pump Models

Owner’s Manual
113863-5-CC 2002 Kohler Co.

Kohler Co., Kohler WI
113863-5-CC 2
IMPORTANT SAFETY INSTRUCTIONS
READ AND FOLLOW ALL INSTRUCTIONS
SAVE THESE INSTRUCTIONS
INSTRUCTIONS PERTAINING TO A RISK OF FIRE, ELECTRIC
SHOCK, OR INJURY TO PERSONS
WARNING: When using this unit, always
follow basic precautions, including the
following:
DANGER: Risk of personal injury. Toreduce
the risk of injury, do not permit children to use
thisunitunlesstheyarecloselysupervisedatall
times.
DANGER: Risk of Injury. Hot whirlpool baths
can put certain stresses on the body, as does
any hot bath, shower, sauna, or steam bath.
Prolonged immersions in hot water may
induce hyperthermia. Symptoms of
hyperthermiaincludeanincreaseintheinternal
body temperature, dizziness, lethargy,
drowsiness, and fainting. The effects of
hyperthermia include (1) failure to perceive
heat,(2)failure torecognizetheneedtoexitthe
bath,(3)unawarenessofimpendinghazard,(4)
fetal damage in pregnant women, (5) physical
inability to exit the bath, and (6)
unconsciousness resulting in the danger of
drowning. Warning – The use of alcohol,
drugs, or other medication can greatly
increase the risk of fatal hyperthermia.
Use this unit only for its intended use as described
in this manual. Do not use attachments not
recommended by Kohler Co.
Do not operate this unit without the guard (cover) on
the suction fitting.
Never drop or insert any object into any opening.
IMPORTANT! Flush your whirlpool system twice a
month or more depending upon usage.
Keep small objects such as bath toys and bathing
accessories out of the whirlpool while the whirlpool
is running.
Repeated use of personal care products containing
oils can damage plastic whirlpool components. Do
not use heavy, vegetable-based shampoos or bath
oils.
The unit must be connected only to a supply circuit
that is protected by Ground-Fault Circuit-Interrupter
(GFCI). Such a GFCI should be provided by the
installer and should be tested on a routine basis.
To test the GFCI, push the test button. The GFCI
should interrupt power. Push the reset button. Power
should be restored.
If the GFCI fails to operate in this manner, the GFCI
is defective. If the GFCI interrupts power to the bath
without the test button being pushed, a ground
current is flowing, indicating the possibility of an
electric shock. DO NOT use this hydro-massage
bath. Disconnect the hydro-massage bath and have
the problem corrected by a qualified service
representative before using.
For Domestic (USA) models only:To reduce the
risk of electric shock, connect only to a properly
grounded, grounding type receptacle, protected by a
Ground-Fault Circuit-Interrupters (GFCI’s). Do not
remove the plug’s ground pin. Do not use a grounding
adapter.
For International models only: (Permanently
connected units.) 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.
A pressure wire connector is provided on the exterior
of the pump 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.
Whirlpool hydro-massage action can cause even a
small amount of bubble bath, bath soap, shampoo, or
bath oil to foam excessively. Refrain from using these
products during whirlpool operation.
Exercise extreme caution if you walk or move around
in the whirlpool, particularly if the whirlpool is running.
Acrylic surfaces are inherently slippery when wet.
Do not allow the water temperature in the whirlpool to
exceed 104F (40C).
Your new whirlpool (USA models only) has been
listed by Underwriter’s Laboratories, thus ensuring
safety for you and your family. Your new whirlpool
also conforms to rigid ANSI and IAPMO standards
set within the plumbing industry.

3113863-5-CC
Kohler Co., Kohler WI
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS 2. . . . . . . .
INTRODUCTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION 4. . . . . . . . . . . . . . . . . . . .
Access Panel Location 4. . . . . . . . . . . . . . . . . . . . . .
Whirlpool Components 4. . . . . . . . . . . . . . . . . . . . . .
Water and Air Flow Cycle 4. . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 5. . . . . . . . . . . . . . . . .
Start-Up Whirlpool 5. . . . . . . . . . . . . . . . . . . . . . . . .
Operating Sequence 5. . . . . . . . . . . . . . . . . . . . . . . .
CARE AND CLEANING INSTRUCTIONS 6. . . . . . .
Cleaning Your Acrylic Whirlpool Bath 6. . . . . . . . .
Cleaning Your Cast Iron Whirlpool Bath 6. . . . . . .
Cleaning Your Gel Coat Whirlpool Bath 6. . . . . . .
Flushing Your Whirlpool System 6. . . . . . . . . . . . . .
TROUBLESHOOT WHIRLPOOL SYSTEM 7. . . . . .
IMPORTANT CONSUMER INFORMATION 8. . . . . .
Requesting Service 8. . . . . . . . . . . . . . . . . . . . . . . . .
Limited One-Year Warranty 8. . . . . . . . . . . . . . . . . .
Lifetime Limited Warranty 8. . . . . . . . . . . . . . . . . . .
1. INTRODUCTION
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.
Identify and record below the model and serial number (found at the pump end of the whirlpool):
Model No. Serial No. Date of Manufacture

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113863-5-CC Kohler Co., Kohler WI
2. THEORY OF OPERATION
A. ACCESS PANEL LOCATION
Access must be provided to perform any service to your
whirlpool. When reading this information, it is a good
idea to open your access panel and familiarize yourself
with the components described below.
After reading this manual, contact your Kohler
dealer if you have any questions.
B. BASIC WHIRLPOOL COMPONENTS
Your new Kohler whirlpool consists of the following
components.
The bath: acts as a reservoir for water and
provides a location for whirlpool action.
The pump actuator: turns the whirlpool on and off
through the activation of a sensing device. This
switch also allows you to regulate the water flow.
The pump-control box: includes the relay and
timer that drive the motor and the pump. This
assembly must be protected with a Class A
Ground-Fault Circuit-Interrupter (GFCI) supplied
by your installer to prevent electrical line-to-ground
shock hazard. Neverbypass the GFCI. If the GFCI
trips or the whirlpool is not working properly, call a
Kohler authorized service representative to repair
the problem.
The 2-speed pump motor unit with built-in
heater: provides the power to move the water and
create the soothing whirlpool action. The built-in
heater engages and remains on to maintain water
temperatureas long as thepump isrunning andthe
whirlpoolwater temperature does not exceed 104°
F (40°C).
Adjustable jets: placed strategically for optimum
hydro-massage. You control the air and water flow
of each jet. The air and water flow is determined by
how far you open up the jet nozzle.
The built-in heater: automatically turns on when
the whirlpool is started, and maintains the water
temperature to a maximum of 104°F (40°C). The
heating element is built into the pump. The heater
is internally wired, and requires no external
electrical connection.
C. WATER AND AIR FLOW CYCLE
The diagram shows the water and air flow for a typical
Kohler whirlpool bath. Once you fill your whirlpool with
water, it becomes a self-contained system.
Water is drawn from the bath through the water suction
inlet located near the bottom of the bath. The water is
pulled into the pump and circulated past the built-in
heater. The water is then forced back into the bath
throughadjustable jets locatedinthe bath walls.Valving
is used to regulate the water flow intensity and/or to
supply water to the neck jets. The suction inlet is
protected with a cover to prevent small objects or hair
from becoming entrapped.
Air is drawn into the stand pipe, mixed with the water
stream at the jets and is adjusted by rotating each
individual jet flange.
The operating cycle continues as long as the pump and
motorarerunning.Abuilt-intimerautomaticallyshutsoff
the pump and motor after 20 minutes of operation.
Water
Suction
Inlet
Required
Access
Panel
Air
Water
Adjustable Jets
Pump/Motor
with Built-in
Heater
Air
Inlet
Adjustable Jets
Adjustable
Jets

5113863-5-CC
Kohler Co., Kohler WI
3. OPERATING INSTRUCTIONS
A. START-UP WHIRLPOOL
Your Kohler Whirlpool Bath promises many hours of
massaging relaxation and enjoyment. Turn on the
whirlpool jets for a vigorous hydro-massage – each jet
can be adjusted individually for optimum air and water
mixture and flow.
Please perform the following so that you may safely
receive the benefits of whirlpool bathing.
To use: Fill your whirlpool bath to a water level 2” to 3”
above the highest jets.
Press the actuator. The whirlpool will operate until:
you press the actuator button again for low-speed
operation. When you press the actuator button a
third time, the pump will shut off.
the whirlpool timer automatically turns off the
whirlpool pump/motor after 20 minutes of
operation.
B. OPERATING SEQUENCE
WARNING: Risk of injury or property damage.
Whirlpool controls are factory installed. Do not
relocate or modify controls as this could adversely
affect safe operation.
Refer to chart for proper operating sequence.
The operating cycle continues as long as the pump and
motorarerunning.Abuilt-intimerautomaticallyshutsoff
the pump and motor after 20 minutes of operation.
Your whirlpool is equipped with a built-in heater. The
heater will automatically cycle on and off to maintain a
maximum 104°F (40°C) water temperature.
Refer to Important Safety Instructions located on
Page 2 of this manual before operating this
whirlpool.
TO METHOD OBSERVE
Turn on high
speed whirlpool
massage (and
the heater, if so
equipped).
Turn on low
speed whirlpool
massage (and
heater, if so
equipped).
To add air and
water to whirlpool
action, rotate
the flange
counterclockwise.
To reduce air and
water, rotate it
clockwise.
Shut off whirlpool.
Restart whirlpool
after 20 minute
cycle is
complete.
Reduce
Air and
Water Add Air
and
Water

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113863-5-CC Kohler Co., Kohler WI
4. CARE AND CLEANING INSTRUCTIONS
A. CLEANING YOUR ACRYLIC WHIRLPOOL
BATH
Do not use abrasive cleansers or solvents on acrylic
surfaces.
Wipe out your acrylic whirlpool with a soft cloth after
each use to prevent a build-up of soap and scum. If the
surface gets excessively dirty you can use a general
purpose cleaner such as: Cinch, Glass Plus, 409All
Purpose, Dow Soap Scum and MildewRemover, Scrub
FreeMildew Remover, Mr CleanLemon Fresh, or
Fantastik. You can also use an automotive-type
polishing compound, followed by an application of
good-quality paste wax.
Avoid cleaning products that contain the following
chemicals, as they will damage the finish of your acrylic
whirlpool: acetone, ethyl alcohol, amyl or ethyl acetate,
sodium hypochlorite, toluene, or phenol.
Extreme heat such as that generated by cigarettes or
portable heaters can damage acrylic surfaces; do not
use such items near your whirlpool.
B. CLEANING YOUR CAST IRON WHIRLPOOL
BATH
Keep your cast iron product looking new by rinsing it out
thoroughly after each use. If the surface gets
excessively dirty, use a general purpose cleaner such
as:CloroxCleanUp,409AllPurpose,Mr. CleanTop
Job, LysolFoaming Disinfectant, Dow Bathroom
Cleaner, or Fantastik.
C. CLEANING YOUR FRP WHIRLPOOL BATH
Wipe your gel coat bathing product with a clean, soft
cloth after each use to prevent a build-up of soap and
scum. If thesurface getsexcessively dirty,useageneral
purpose cleaner such as: Scrub FreeSoap Scum
Remover, 409All Purpose, Mr. Clean Lemon Fresh,
Glass Plus, or Fantastik. You can also use an
automotive-type polishing compound, followed by an
application of good-quality paste wax.
Do not use abrasive cleansers or solvents on gel coat
bathing products.
Avoid cleaning products that contain the following
chemicals,astheywilldamagethefinishofyourgelcoat
bathing product: acetone, ethyl alcohol, amyl or ethyl
acetate, sodium hypochlorite, toluene, or phenol.
Extreme heat such as that generated by cigarettes or
portable heaters can damage gel coat surfaces; do not
use such items near your bathing product.
D. FLUSHING YOUR WHIRLPOOL SYSTEM
Flush your whirlpool system twice a month or more,
depending upon usage. Use the following sequence:
Adjust the jets so there is no air induction;
Fill the whirlpool with hot water to a level above the
back jet water sensors;
Add 2 teaspoons of a low-foaming dishwasher
detergent, and 1/2 cup of household bleach to the
water;
Run the whirlpool for 5 to 10 minutes in each
massage mode; then drain;
Fill with cold water to a level above the back jet
water-level sensors, and run the whirlpool for
another 5 to 10 minutes in each massage mode.
Drainthewhirlpool, and wipeitdry with asoftcloth.

7113863-5-CC
Kohler Co., Kohler WI
5. TROUBLESHOOT WHIRLPOOL SYSTEM
Thistroubleshootingguideisforgeneralaidonly. A KohlerAuthorizedServiceRepresentativeoraqualifiedelectrician
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 motor. A. Set/Reset GFCI/ELCB breaker; check wiring. If problem persists, refer to
installer/dealer.
B. Faulty switch. B. Replace switch. Refer to installer/
dealer.
C. Jets are blocked. C. Remove blockage. Refer to installer/
dealer.
D. Faulty circuit board. D. Replace circuit board. Refer to
installer/dealer.
E. Switch disconnected from panel. E. Reconnect wire at switch or at pump.
Refer to installer/dealer.
F. Faulty motor/pump assembly. F. Replace motor and pump. Refer to
installer/dealer.
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. Refer to installer/dealer.
C. Jets are blocked. C. Remove blockage.
3. Whirlpool stops
automatically
before 18 minutes.
A. GFCI/ELCB trips. A. Identify source of fault and correct. If
problem persists, refer to
installer/dealer.
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.
Check for suction blockage. Remove
blockage and allow motor to cool.
Check for jet blockage. Remove
blockage and allow motor to cool.
E. Faulty circuit board. E. Replace circuit board. Refer to
installer/dealer.
4. Whirlpool does not
automatically stop
after 22 minutes.
A. Faulty circuit board. A. Replace circuit board. Refer to
installer/dealer.
5. Jet squeals/is noisy. A. O-ring unseated. A. Remove jet and replace O-ring onto
jet valve body; reinstall jet. Refer to
installer/dealer.
6. Whirlpool is noisy. A. Shipping straps holding pump to bath
have not been cut. A. Cut straps so pump sits on subfloor.

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113863-5-CC Kohler Co., Kohler WI
6. IMPORTANT CONSUMER INFORMATION
A. REQUESTING SERVICE
Please take a moment to familiarize yourself with the
Kohler Warranty, its benefits, and limitations. Kohler Co.
and its distributors support you with one of the largest
ServiceNetworks of itstype. Here’swhatyouneedtodo
if you require service:
1. Contact the dealer or contractor who sold and
installed the product. They should be able to solve
any problems you may have.
2. If your dealer or contractor cannot solve the
problem, they will contact or supply you with the
name of the local Kohler Distributor and the:
KOHLER TECHNICAL SPECIALIST
3. If you areunable toobtain warranty servicethrough
either your contractor or Kohler Co. distributor,
please write us directly at Kohler Co., Attn:
Customer Service Department, 444 Highland
Drive, Kohler, WI 53044 USA, or call
1-800-4-KOHLER from within the USA.
4. Include all pertinent information regarding your
claim, including a complete description of the
product, model numbers, colors, finishes, and the
datetheproductwasinstalled.Includeadescription
of the problem, and a photocopy of your invoice for
the products involved. Also give us the name of the
contractor and distributor.
B. LIMITED ONE-YEAR WARRANTY -ACRYLIC
ANDFRP
Kohler plumbing fixtures and fittings are warranted free
of manufacturing defects.
Kohler Co. will, at its election, repair, replace, or make
appropriate adjustment where Kohler Co. inspection
discloses any such defects occurring in normal usage
within one year after installation. Kohler Co. is not
responsible for installation or removal costs.
To obtain warranty service, contact Kohler Co. either
through your Dealer or Plumbing Contractor, or by
writing Kohler Co., Attn: Customer Service Department,
444HighlandDrive,Kohler,WI53044USA,or by calling
1-800-4-KOHLER from within the USA.
Implied warranties, including that of
merchantability or fitness for a particular purpose,
are expressly limited in duration to the duration of
this warranty. Kohler Co. disclaims any liability for
special, incidental, or consequential damages.
Some states do not allow limitations on how long an
implied warranty lasts or the exclusion or limitation of
special, incidental, or consequential damages, so these
limitations and exclusions may not apply to you. This
warranty gives you specific legal rights. You may also
have other rights which vary from state to state.
This limited warranty provides specific legal rights as
they apply within the USA, and other rights may be
available, but may vary from country to country.
This is our exclusive written warranty.
KOHLER CO., KOHLER, WISCONSIN 53044
C. LIFETIME LIMITED WARRANTY – CAST IRON
Kohler warrants this cast iron product to be free of defects in material and workmanship during normal residential use for as long
as the original purchaser owns his/her home. Gloss reduction, scratching, staining or alkaline etching, of the finish over time due
to use, cleaning practices or water or atmospheric conditions are not manufacturing defects but are indicative of normal wear and
tear. This warranty is applicable to Kohler cast iron product manufactured after February 10, 2000.
Ifadefectisfoundinnormalresidentialuse,KohlerCo.will,atitselection,repair,replaceormakeappropriateadjustment. Damage
caused by accident, misuse, or abuse is not covered by this warranty. Improper care and cleaning will void the warranty. Proof of
purchase(originalsalesreceipt)mustbeprovidedtoKohlerwithallwarrantyclaims. KohlerCo.isnotresponsibleforlaborcharges,
installation, or other consequential costs. In no event shall the responsibility of Kohler exceed the purchase price of the product.
Toobtainwarrantyservice,contactKohlerCo.throughyourDealerorPlumbingContractor,orbywriting:KohlerCo.,Attn:Customer
Service Department, 444 Highland Drive, Kohler, WI 53044, USA, or by calling 1-800-4-KOHLER from within the USA,
1-800-964-5590 from within Canada, or 001-877-680-1310 from within Mexico. Please be sure to provide all pertinent information
regarding your claim, including a complete description of the problem, the product, model number, color and the date the product
was purchased. Also include the name of your contractor or distributor and your original invoice.
Iftheproductisusedcommercially,Kohlerwarrantstheproducttobefreefromdefectsinmaterialandworkmanshipforone(1)year
from the date of purchase as shown on the invoice or receipt with all other terms of this warranty applying except duration. Any
impliedwarrantiesforproductusedcommercially,includingthatofmerchantability orfitnessforaparticularpurpose, are
expressly limited in duration to the duration of the one year express warranty.
To the extent permitted by law, Kohler Co. disclaims all implied warranties including merchantability and fitness for a
particular purpose. Kohler Co. disclaims any liability for special, incidental, or consequential damages. Some
states/provinces do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of special, incidental,
or consequential damages, so these limitations and exclusions may not apply to you. This warranty gives you specific legal rights.
You may also have other rightswhich varyfrom state/provinceto state/province. This warrantyis tothe originalpurchaser only and
excludes product damage due to installation error, product abuse, or product misuse, whether performed by a contractor, service
company, oryourself. Thiswarranty appliesonly for Kohlercast iron productinstalled inthe UnitedStatesof America,Canadaand
Mexico.
This is our exclusive written warranty.