Kohler 10-Jet K-1000-H2 User manual

Installation Guide
10-Jet Corner Hydro-Massage System
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-1000-H2, K-1005-H2, K-5162
1032108-2-D

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) or Earth-Leakage Circuit-Breaker (ELCB).
Two dedicated 220-240 V, 20 A, 50/60 Hz services are required. Each must be protected by a GFCI or ELCB.
A pressure wire connector marked ″Ground″is provided within each wiring compartment. To reduce the risk
of electric shock, connect this connector to the grounding terminal of your electric service or supply panel
with a copper wire 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. Use this
connector as a bonding conductor between this unit and all of the exposed metal in the vicinity, as needed to
comply with local requirements.
Provide access to components for servicing.
Grounding is required. The unit should be installed and grounded by a qualified service representative.
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
Product Modifications
WARNING: Unauthorized modifications may cause unsafe operation and poor performance of
the custom system. Do not remove the pump from the pump box or make non-recommended
modifications to the system. Unauthorized modifications could adversely affect the performance
and safe operation of the unit. Kohler Co. shall not be liable under its warranty, or otherwise, for
personal injury or damage caused by any unauthorized modification.
The system is not designed for steam applications, and may not perform in a satisfactory manner as a steam
unit.
Product Inspection
Carefully unpack and inspect all components for damage. Return all materials to the cartons during
construction to prevent damage.
Factory-Assembled Features
Some components have been factory installed and others will require assembly. Components include a tower
with ten pre-assembled jets, a waterfall, a pump, a heater, a control, a footbath and an enclosure.
Connections and Service Access
Before installation, ensure proper access to the final connections.
NOTICE: Provide unrestricted service access to the pump. You must provide access for servicing the
pump, heater and control. The access must be located immediately next to the pump.
1032108-2-D 2 Kohler Co.

Product Information (cont.)
Electrical Requirements
The installation must have two Ground-Fault Circuit-Interrupters (GFCI) or Earth-Leakage Circuit-Breakers
(ELCB). The GFCI or ELCB protects against line-to-ground shock hazard. Use a 220-240 V, 20 A, 50/60 Hz
dedicated service for the pump and control. Use a separate 220-240 V, 20 A, 50/60 Hz dedicated service for
the heater.
Table of Contents
Important Information .............................................................. 2
Product Information ............................................................... 2
Product Modifications ............................................................ 2
Product Inspection .............................................................. 2
Factory-Assembled Features ...................................................... 2
Connections and Service Access ................................................... 2
Electrical Requirements .......................................................... 3
Before You Begin ................................................................. 4
Tools and Materials ............................................................... 4
Framing Preparation .............................................................. 5
Plumbing Preparation .............................................................. 6
Install the Footbath ............................................................... 6
Construct the Apron ............................................................... 7
Install Plumbing .................................................................. 8
Tower Mounting Frame Preparation ................................................... 8
Install the Tower Mounting Frame ..................................................... 8
Connect the Suction Assembly ....................................................... 9
Connect the Tower and Pump ...................................................... 10
Make Electrical Connections ........................................................ 11
Install the Wall Jambs ............................................................ 13
Apply Silicone Sealant ............................................................ 13
Complete the Finished Wall ........................................................ 14
Install the Side Panels ............................................................ 15
Install the Header ................................................................ 15
Secure the Side Panels ........................................................... 16
Set the Header Height ............................................................ 17
Hang the Door Panels ............................................................ 18
Adjust Header Height ............................................................. 19
Install the Side Jamb Seals ........................................................ 20
Adjust the Side Door Panels ........................................................ 20
Adjust the Center Door Panel ....................................................... 21
Install the Backstop .............................................................. 21
Install the Door Handles ........................................................... 22
Adjust the Stop Blocks ............................................................ 22
Apply Sealant to the Door ......................................................... 23
Install the Tower ................................................................. 25
Complete the Tower Installation ..................................................... 25
Faucets and Fittings .............................................................. 25
Install the Keypad ............................................................... 26
Install the Seat .................................................................. 27
Water Test the System ............................................................ 27
Clean Up After Installation ......................................................... 27
Troubleshooting Procedures ........................................................ 28
Kohler Co. 3 1032108-2-D

Before You Begin
IMPORTANT! The hydro-massage system is intended for indoor use only.
IMPORTANT! The stud supports must be within 3/8″(1cm) of plumb. The door enclosure is designed to
fit the footbath. Proper door assembly and operation depends upon installation of the footbath against
square and plumb studding.
The hydro-massage system operates at flow rates up to 80 gallons (302 L) 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.
It is critical that you follow the installation sequence and details in the steps that follow to
successfully install and operate your system, and to prevent costly repairs and rework.
Kohler Co. shall not be responsible for leakage that occurs as a result of inadequate or poor
assembly or installation techniques.
All information in this manual is based on the latest product information available at the time of
publication. At Kohler, we constantly strive to improve the quality of our products. We reserve the
right to make changes in product characteristics, packaging or availability at any time without
notice.
Tools and Materials
Plus:
• Conventional Woodworking
Tools and Materials
• Plumbing Tools and
Equipment
• Drop Cloth
• 2x4s or 2x6s
• Plywood
• Cement Board
• Solvent Welding Solution
• Pencil
Masking
Tape
Shims Level Claw
Hammer
1-5/8" Carbide
Hole Saw
Drill Bits
Safety
Glasses
Measuring
Tape
Silicone
Sealant
1032108-2-D 4 Kohler Co.

1. Framing Preparation
NOTE: Carefully study the roughing-in pages and the illustration above before you construct the framing.
Follow the framing details carefully.
IMPORTANT! The stud supports must be within 3/8″(1 cm) of plumb. The door enclosure is designed to
fit the footbath. Proper door enclosure assembly and operation depends upon installation of the footbath
against square and plumb studding.
Use 2x4 framing. Choose a preferred side for installing the pump and provide sufficient access
accordingly. Refer to the roughing-in information for further details.
The distance from the rough floor to the finished ceiling or header must be between 83-1/2″(212.1
cm) and 84″(213.4 cm) to provide adequate clearance when assembling the door enclosure to the
footbath.
Make sure the ceiling and header are level.
Provide double stud support for the door enclosure wall jambs. You must secure the door enclosure
wall jams 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.
The stud supports must be plumb for proper door operation. Maintain a maximum tolerance of
3/8″(1 cm) 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 as needed.
IMPORTANT! Leave studs exposed. You must secure the door enclosure wall jambs directly to the studs.
Do not install the finished wall material until instructed.
If you plan to install grab bars or other accessories, provide sufficient backing.
52" (132.1 cm)
*29" (73.7 cm)
*Pump/Control Access
(can be provided on
either side)
Double Stud (required for
door installation)
Attach tower
piping here.
Side ViewTop View
Double Stud (required for
door installation)
18-7/8"
(47.9 cm)
18-7/8"
(47.9 cm)
52"
(132.1 cm)
12"
(30.5 cm) 14"
(35.6 cm)
12"
(30.5 cm)
10-3/4"
(27.3 cm)
83-1/2"
(212.1 cm)
to 84"
(213.4 cm)
12"
(30.5 cm)
Use 2x4s on corners.
*Pump/Control Access can
be provided on either side.
Allow for protrusion.
14" (35.6 cm)
Kohler Co. 5 1032108-2-D

2. Plumbing Preparation
Position the plumbing supplies and drain trap according to the roughing-in dimensions. Cap the
supplies and check for leaks.
Install the drain on the footbath according to the drain manufacturer’s instructions. When installing
the drain overflow tube and hood, be sure to adequately seal along the edges of the hood to prevent
leakage.
3. Install the Footbath
Double studs for the wall jambs must be square and plumb within 3/8″(1 cm) for proper door
installation.
The pump is detached from the footbath harness for ease of transport. Additional components are
shipped with the unit in kit form. Remove these and place them next to the pump for later
installation.
Set the footbath on the subfloor. Align the trap with the tailpiece.
Position a clean drop cloth in the footbath to prevent damage.
Confirm that the footbath is level using a level on the rim surfaces. Do not use the nailing-in flange
to level the unit.
NOTE: The footbath must be level to properly install and operate the door.
Place shims under the wood blocks as needed to level the footbath.
NOTE: Drill the holes in the nailing-in flange from the finished side to avoid chipping the acrylic.
From the finished side of the nailing-in flange, drill and countersink the pilot holes halfway up the
nailing-in flange at each stud location. Use galvanized drywall screws to secure the footbath to the
studs.
Add furring strips to the stud framing inside the recess area to ensure the studs are even with the
nailing-in flange.
2-3/8"
(6 cm)
1032108-2-D 6 Kohler Co.

4. Construct the Apron
NOTE: Kohler recommends this procedure to construct the apron. Other methods can be used to obtain an
acceptable result.
Cut four 3/4″plywood boards to 6″(15.2 cm) x 28-1/2″(72.4 cm). Measure and cut a 60° taper at
one end of each board, and a 75° taper at the other end. Both ends must taper to the same side.
Draw a pencil mark 2-1/2″(6.4 cm) from the long side of one of the boards at the 75° taper end.
Draw a second mark 4-1/2″(11.4 cm) from the long side, as shown above.
Use a pencil, string and nail to carefully draw a 51-1/4″(130.2 cm) radius (for 1/2″(1.3 cm) thick
finished wall) across the full length of the board at the 2-1/2″(6.4 cm) pencil mark. For different
finished wall thickness, adjust this radius accordingly. Draw a 49-1/4″(125.1 cm) radius across the
4-1/2″(11.4 cm) pencil mark.
Use a saber saw to cut the plywood along the radius lines.
Use this board as a template to mark and cut the other three plywood boards.
Cut four 3/4″plywood boards to 2″(5.1 cm) x 15-1/2″(39.4 cm).
Cut sixteen 2x2 studs 9″(22.9 cm) long.
Assemble the apron frame sections as shown.
Position the apron frame sections under the footbath 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.
Secure the apron frame sections to the floor.
3/4" Plywood
3/4" Plywood
2x2 Studs
10-1/2"
(26.7 cm)
9"
(22.9 cm)
28-1/2" (72.4 cm)
6" (15.2 cm)
4-1/2"
(11.4 cm)
2-1/2"
(6.4 cm)
Measure 2-1/2" (6.4 cm)
and 4-1/2" (11.4 cm)
down from this edge.
49-1/4"
(125.1 cm) R.
51-1/4" (130.2 cm) R.
75˚ 60˚
Kohler Co. 7 1032108-2-D

5. Install Plumbing
CAUTION: Risk of damage to the 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. Make sure to
plug the suction line if the pump is not yet attached.
NOTE: An access panel will simplify future maintenance.
6. Tower Mounting Frame Preparation
The location of the tower mounting frame is critical. Be precise with this measurement.
Measure 2-3/8″(6 cm) from the deck surface of the footbath to the tower mounting stud. Draw a
pencil line at that location.
7. Install the Tower Mounting Frame
Remove the three 3/8″tower bolts and carefully lift the tower out of the mounting frame. Carefully
set the tower aside where it will not be damaged.
Position and level the mounting frame between the tower mounting studs and align 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 the 10 provided drywall screws.
2-3/8"
(6 cm)
Nailing-In
Flange
Mounting
Frame
Pencil Line
Drywall
Screw
Mounting
Studs
Bolts
Bolt
1032108-2-D 8 Kohler Co.

8. Connect the Suction Assembly
Orient the Pump
Remove the pump from the shipping box and position it near where it will be installed.
NOTE: The pump and control must be properly oriented for your installation. If the pump is facing the
proper direction and the cooling fins face away from the footbath, as shown in the illustration, proceed to
Install the Suction Assembly.
The pump should be oriented with the control cooling fins situated away from the footbath.
If the cooling fins are not properly oriented, detach the pump from the control by removing the four
nuts.
Turn the pump 180° so it is facing in the opposite direction.
Confirm that the cooling ribs are properly situated and re-attach the four nuts.
Securely tighten the nuts.
Install the Suction Assembly
Locate the heater subassembly. It is located in the kit that was packed with the pump.
Orient the heater subassembly so that it will connect the suction line to the pump. This step will
determine the final position of the pump.
Position the O-ring and attach the heater end of the assembly to the suction line.
Position the O-ring and attach the opposite end of the assembly to the pump.
Pump
Ensure minimum 1/4"
(6 mm) pitch per foot
(30.5 cm) toward
suction assembly.
Place cooling fins to
the outside of pump.
Heater Subassembly
Suction Line
Pump
Pump
Pump Drainage
Kohler Co. 9 1032108-2-D

9. Connect the Tower and Pump
NOTE: If the pump was shimmed up in the previous step, you may need to move the tower mounting
frame up an equivalent distance. Check for clearance before moving the tower mounting frame.
Position the O-ring and loosely hand tighten the union nut, elbow and tee assembly to the pump.
Orient the assembly to face the mounting frame.
Check to make sure that all piping from the pump to the suction intake fitting is sloped at least
1/4″(6 mm) per foot (30.5 cm). If not, shim under the pump to achieve the required slope.
Locate the threaded adapter, the 1-1/4″x 90° street elbow, the 1-1/4″x 45° street elbow, and the
piece of flexible hose.
Dry fit the components by assembling them as shown in the illustration. Measure and cut the
section of flex hose if necessary.
Check for appropriate clearances and maintain a minimum 1/4″(6 mm) per foot (30.5 cm) pitch
between the tower and the pump. Move the tower mounting frame up, if necessary. Maintaining a
constant downslope pitch from the tower is important to draining the system and preventing
cavitation of the pump due to an air lock.
Use PVC primer and glue to secure the joints once the parts have been properly positioned.
Position the O-ring and connect the adapter fitting to the mounting frame union nut.
Secure all nut fittings until each of them are hand tight, plus 1/4 turn more (maximum). Do not
overtighten.
Mounting Frame
Union Nut
1-1/4" x 45˚ PVC
Street Elbow
Pump
O-Ring
O-Ring
O-Ring
Measure and
cut to length.
1-1/4" x 90˚ PVC
Street Elbow
Flex Hose (supplied)
Pressure Switch
Mounting Frame
Threaded
Adapter
Heater
Subassembly
1032108-2-D 10 Kohler Co.