Kohler K-163 User manual

Installation Guide
Pedicure Spa
K-163, K-1006, K-1011,
K-1012
1063564-2-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).
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 footbath.
NOTE: If the pump supply cord is damaged, it must be replaced by the manufacturer, its service agent or
similarly qualified person in order to avoid a hazard.
Product Notices
WARNING: Unauthorized modification may cause unsafe operation and poor performance of the
footbath. Do not relocate the footbath pump, or make other modifications to the footbath system, as
this could adversely affect the performance and safe operation of the footbath. 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
Pump with power supply cord is factory installed. No installation is needed.
The pump and piping are factory-assembled.
Connections and Service Access
Before installation, ensure proper access to the final pump and faucet connections.
1063564-2-D 2 Kohler Co.

Table of Contents
Important Information .............................................................. 2
Thank You For Choosing Kohler Company .............................................. 4
Tools and Materials ............................................................... 4
Before You Begin ................................................................. 4
Construct the Platform Framing ...................................................... 5
Provide Electrical Service ........................................................... 6
Route Plumbing .................................................................. 6
Install the Footbath ............................................................... 7
Complete the Platform Framing ...................................................... 8
Prepare the Rough Deck Material ..................................................... 9
Begin Tiling the Platform .......................................................... 10
Install the Faucet and Air Switch ..................................................... 11
Cut the Pump Banding Straps ...................................................... 11
Check Installation and Operation .................................................... 12
Complete the Platform ............................................................ 13
Install the Client Chair (If Used) ..................................................... 14
Cleaning the Cast Iron Surface ...................................................... 14
Troubleshooting Procedures ........................................................ 15
Kohler Co. 3 1063564-2-D

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 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 footbath by the pump or piping, or use the
pump or piping for structural support of the footbath.
IMPORTANT! This guide covers the installation for the components included with the K-163 pedicure spa
(footbath, faucet and drain components, client chaise lounge, and technician chair). If using other
components, the installation may need to be adjusted to accommodate your specific installation
requirements.
IMPORTANT! This installation requires the use of floor-grade tiles for the finished deck surface. Do not
use wall tiles for the deck surface.
IMPORTANT! All dimensions provided for the construction of the framing assume 1/2” (1.3 cm)
rough-deck material and 1/4” (6.4 cm) thick tile for the finished deck. If using other materials, adjust the
height of the stud framing accordingly to meet the required finished height of the deck.
Observe all local plumbing and building codes, including backflow protection.
The footbath is designed for tile-in installations.
Prior to installation unpack the footbath and inspect it for damage. Return the footbath to its
protective carton until you are ready to install it.
The provided instructions describe use of all three Kohler products. If used separately, please refer
to the individual product instructions.
Due to the variety of installations possible with this product, you may need to use procedures other
than those described in this guide.
Proper selection of tile is critical. Once selected, provide a sample of the tile to each contractor.
Because of the variance in material thicknesses, communication between the carpenter, tile layer, and
plumber is essential when planning this installation.
Kohler Co. reserves the right to make revisions in the design of products without notice, as specified
in the Price Book.
Plus:
• Common woodworking tools and materials
• Hole Saw
• Nails/Drywall Screws
• High-quality 1x4s, 2x4s and plywood
• Water-resistant underlayment or sealant
• Rough-deck and side material (1/2" recommended)
• Floor grade tile (1/4" recommended)
• Tiling Supplies
• Scissors
Pencil
Square
Level
Safety
Glasses
Tape
Measure
Sealant Silicone Drill
Claw
Hammer
1063564-2-D 4 Kohler Co.

1. Construct the Platform Framing
IMPORTANT! The dimensions in the illustrations above assume 1/2″(1.3 cm) rough deck and 1/4″(6.4
cm) tile thickness. If using other materials/thicknesses, the frame dimensions will need to be adjusted
accordingly but must be no smaller than shown in the diagram above to allow proper air circulation for
the pump.
Construct the platform framing to ensure a finished platform height of 24″(61 cm).
NOTE: Secure all frame components except the footbath sled supports and the front bump-out (to be
constructed later).
Construct the platform framing according to the illustration above. Cover the kick-plate with
plywood. Lay the two footbath sled supports onto the stacked 2x4 supports but do not secure at this
time.
Optional: Construct steps, adjacent to the platform, opposite the faucet installation location. Two
steps, are recommended, measuring 28-1/2″(72.4 cm) wide with an 8″(20.3 cm) rise and a 12″(30.5
cm) run.
Do not assemble until
footbath is installed.
Footbath sled supports must
be a 2" (5.1 cm) thickness.
49" (124.5 cm)
28-1/2" (72.4 cm)
43"
(109.2 cm)
39-1/2"
(100.3 cm) 22-1/2"
(57.2 cm)
4-1/2"
(11.4 cm)
5-1/2"
(14 cm)
23-1/4"
(59.1 cm)
35"
(88.9 cm)
28"
(71.1 cm) 72" (182.9 cm)
8"
(20.3 cm)
1-7/16"
(3.7 cm)
18-1/2"
(47 cm)
19"
(48.3 cm)
Kohler Co. 5 1063564-2-D

2. Provide Electrical Service
WARNING: Risk of electrical shock. Disconnect the power before proceeding. Refer to the
″Important Information″section.
A Ground-Fault Circuit-Interrupter (GFCI) is required for this circuit.
Refer to the roughing-in information to determine the proper outlet location.
Provide a 120 V, 15 A, 60 Hz dedicated circuit.
IMPORTANT! A licensed electrician must install a GFCI-protected, 120 V, 15 A grounded outlet. No other
load should be on this circuit.
Route the electrical supply and install an outlet within 24” (61 cm) of the pump installation location.
Do not connect the power until directed to do so.
3. Route Plumbing
NOTE: Faucet can be installed on either the left- or right-side of the footbath. All illustrations show
right-side faucet installations.
NOTE: The air switch will need to be installed on the same side of the platform as the faucet.
Determine which side of the footbath that the faucet will be installed.
Temporarily slide the footbath sled into the framing.
Position the footbath sled a minimum of 8-1/4″(21 cm) from the outside edge of the faucet-side of
the platform framing. Verify that there is adequate space between the framing and the footbath for
the faucet valving.
With a pencil, mark the footbath position on the frame.
Note the location of the footbath drain outlet.
If necessary, move the sled supports as needed to not interfere with the drain connections.
Remove the footbath and return it to the carton.
Install the rough water supply and drain piping.
IMPORTANT! When required by local codes, install a RPZ backflow prevention device to each faucet
supply line.
Supply Stops
Sled Supports
Locate the electrical outlet
within 24" (61 cm) of pump.
8-1/4" (21 cm) Min
(clearance for faucet)
Recommended faucet install
location (either side of footbath)
Footbath Sled
When required, install a RPZ
to each faucet supply line.
1063564-2-D 6 Kohler Co.

4. Install the Footbath
CAUTION: Risk of property damage. Ensure a watertight seal on all drain connections.
IMPORTANT! Do not remove the footbath or pump from the footbath sled. The footbath, pump, and sled
will be installed as a single unit.
IMPORTANT! Install the drain using the gasket provided in the footbath literature pack, not the gasket
packet with the drain.
Install the drain to the footbath according to the instructions packed with the drain.
Slide the footbath sled into the framing. Position according to the pencil marks on the framing.
If necessary, move the sled supports as needed to not interfere with the drain connections.
Secure the sled supports to the 2x4 supports and the footbath to the sled supports.
Connect the drain to the trap according to the drain installation instructions.
Footbath Sled
Sled Supports
Recommended faucet install
location (either side of footbath)
Kohler Co. 7 1063564-2-D

5. Complete the Platform Framing
NOTE: The bump-out will be positioned off-center due to the footbath being positioned to allow room for
the faucet.
Build a bump-out, using 1x4s, for the platform frame to accommodate the front footbath jet. This
bump-out will allow the technician to sit closer to the footbath basin.
Install the bump-out to complete the platform framing.
3"
(7.6 cm) 9-1/2"
(24.1 cm)
7-3/4"
(19.7 cm)
3-1/2"
(8.9 cm)
10-3/4"
(27.3 cm)
6"
(15.2 cm)
1-1/4"
(3.2 cm)
1-3/4"
(4.4 cm)
1-3/4"
(4.4 cm)
1/2"
(1.3 cm)
Complete the Platform Framing
Bump-out Frame Detail
Measure from
faucet install side.
35"
(88.9 cm)
28"
(71.1 cm)
1063564-2-D 8 Kohler Co.

6. Prepare the Rough Deck Material
CAUTION: Risk of product damage. Do not cut the rough deck near the footbath.
Verify the position of the footbath and mark the location on the deck material.
Locate the access panel. The access panel should be a minimum of 21″(53.3 cm) x 12 (30.5 cm) and
located directly over the pump.
Mark the cutout for the footbath and access panel onto the deck material.
Cut out the opening for the footbath and access panel in the deck material.
Provide support around the edges of the access panel cutout to prevent the panel from falling
through.
Cut out the footbath opening.
Access Panel
Prepare the Rough Deck Material
22"
(55.9 cm)
6-1/8"
(15.6 cm)
12"
(30.5 cm)
21"
(53.3 cm)
21"
(53.3 cm)
Kohler Co. 9 1063564-2-D

7. Begin Tiling the Platform
NOTE: Allow access to the pump connections.
Install the rough deck material to the platform.
Seal the rough deck or install a waterproof barrier over the rough deck material.
NOTE: The holes for the faucet, handspray, air switch, and client chair legs should be drilled through the
rough deck and tile prior to the tile being installed.
IMPORTANT! Leave an opening on the faucet-side of the platform to allow access for installing the faucet
components and air switch. Do not cover this opening until the system has been checked.
Install the side material to the platform.
IMPORTANT! Faucet should be located as to not interfere with the client chair operation, especially any
that are adjustable front-to-back.
NOTE: For ease of installation and operation, locate the faucet and air switch controls on the same side of
the platform.
Mark the hole locations for the faucet, handspray, air switch, and K-1011 client chair (if used) legs.
Refer to the above illustration for hole sizes; drill the holes for the faucet, handspray, air switch, and
client chair legs at the marked locations.
Pre-cut or drill the tile as needed to align with the holes drilled in the rough deck.
Install the tile to the platform. Do not cover the access on the faucet-side of the platform at this
time.
IMPORTANT! Allow the tile adhesive and grout to cure according to the manufacturers’ instructions
before proceeding.
Air Switch Location
Top View of Rough Deck
Faucet Component and Chair Leg Locations
1-7/8" (4.8 cm) D.
4-1/4" (10.8 cm)
4-3/4" (12.1 cm)
Supplies
Do not cover until the air switch and
faucet components are installed.
Cover access and complete tile
after installation is checked.
Tile platform, sides and top access panel.
39-1/8" (99.4 cm)
1-1/2"
(3.8 cm) D. 1-1/4"
(3.2 cm) D.
8-1/4"
(21 cm)
1-1/4"
(3.2 cm) D.
11-1/4"
(28.6 cm)
4"
(10.2 cm)
5-3/4"
(14.6 cm)
19-3/4"
(50.2 cm)
7/16"
(1.1 cm) D.
1063564-2-D 10 Kohler Co.

8. Install the Faucet and Air Switch
Install the faucet components to the platform according to the instructions packed with the
products.
Connect the hose from the diverter to the back of the footbath fill spout.
Remove the nut from the air switch assembly.
Verify the tube is firmly attached to the air switch assembly.
Apply a small bead of silicone sealant around the backside of the air switch flange.
Feed the tube through the air switch hole.
Insert the air switch assembly into the hole and press firmly. Wipe away any excess sealant.
Slide the nut over the tube. Secure the air switch assembly to the platform with the nut.
Attach the free end of the tube to the pump and secure with the nut until finger-tight.
9. Cut the Pump Banding Straps
Cut the pump banding straps.
Fill Spout
Connect air switch
hose to the pump.
Connect the hose from the diverter to
the fill spout.
Cut the banding straps.
Platform
Flange
Apply silicone sealant.
Tube
Nut
Install the Faucet
Install the Air Switch
Kohler Co. 11 1063564-2-D

10. Check Installation and Operation
Plug the pump into the outlet.
Verify that the electrical supply to the outlet is on.
Verify that the pump banding straps have been cut, and that the pump is resting directly on the
footbath sled.
Turn on the water supplies and check all connections for leaks.
Position the jet nozzles to point toward the bottom of the footbath.
Verify the air switch tubing is securely attached to the pump, and is not kinked or damaged.
Fill the footbath to a level at least 2” (5.1 cm) above the highest jet.
Press the air switch to turn on the footbath.
Allow the footbath to run for approximately 5 minutes and check all piping connections for leaks.
Rotate the jet trim rings to increase (counterclockwise) or decrease (clockwise) the flow.
Press the air switch again to turn off the footbath.
Fill with water at least 2" (5.1 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 switch to turn the
whirlpool on or off.
1063564-2-D 12 Kohler Co.

11. Complete the Platform
Cover the platform opening and finish tiling the side of the platform.
Finish tile here.
Tile
Cover and complete
tile installation.
Kohler Co. 13 1063564-2-D

12. Install the Client Chair (If Used)
Insert a dowel (supplied) into each of the four holes in the platform.
With help, lift the chair onto the platform.
Align the holes in the chair legs with each of the dowels.
Lower the chair legs onto the dowels.
13. Cleaning the Cast Iron Surface
When cleaning up after installation, do not use abrasive cleansers, as they may scratch and dull the
footbath 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 footbath 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.
Refer to the Maintenance Guide for additional cleaning information.
1/2" (1.3 cm)
Dowel
Pump Access Panel
1063564-2-D 14 Kohler Co.

Troubleshooting Procedures
Remove the Factory Installed Jets
NOTE: A special tool is provided with the replacement jets that will allow you to remove the jets from the
footbath. This tool is also supplied with each trim kit.
Position the jet ball nozzle so it is pointing upward.
NOTE: The nozzle must remain pointed up or the tool will slip off.
Insert the removal tool, hooked end up, into the opening of the jet and hook the inside top of the
nozzle.
Grasp the tool firmly and place your thumb against the footbath wall. Pull steadily on the tool until
the jet assembly pulls free of the hole. Be careful not to lose the O-ring.
Reinstall the Jets
NOTE: The jet O-ring must be correctly positioned, must be lubricated, and must be in good condition to
permit easy rotation and proper operation of the jet.
Install the O-ring onto the first shoulder of the jet. Lubricate the O-ring with silicone lubricant to
prevent noisy operation of the jet.
Carefully insert the jet into the housing, and lightly push and rotate the jet until it snaps into
position. Do not force the jet.
NOTE: When installed correctly, the jet should turn smoothly both clockwise and counterclockwise.
Troubleshooting Guide
This troubleshooting guide is for general aid only. A Kohler Authorized Service Representative or qualified
electrician should correct any electrical problems. For warranty service, contact your dealer or wholesale
distributor.
Symptoms Probable Causes Recommended Action
1. Footbath does not start or
stop.
A. No power to motor. A. Check that the pump and heater
are plugged in and that the GFCI
is switched to the correct
position. Plug in or reset the
GFCI as needed.
B. Air hose is loose or disconnected. B. Check that the hose is connected
at both the receiver/pump end
and to the air switch. Reconnect
if needed.
Remove the Jets
Insert the tool hook as shown and pull the jet out of the
housing. The jet should be facing up when this is done.
Housing
Reinstall the Jets
Insert the jet into the housing, and lightly
push and rotate until it snaps in position.
Slide the O-ring
onto the first
shoulder of the jet.
Inspect and
lubricate the O-ring.
Kohler Co. 15 1063564-2-D

Troubleshooting Procedures (cont.)
Symptoms Probable Causes Recommended Action
C. Air hose is pinched or kinked. C. Adjust hose to clear the
pinched/kinked area. If the
tubing is pinched/kinked and
cannot be readjusted, or no
noticeable pinch/kink is
apparent, poke a small hole in
the tubing with a tack and try
the system again.
D. Part(s) of the push button
assembly is/are damaged.
D. Replace the push button
assembly.
E. Push button has grease in the
bleed area.
E. Disassemble the push button
assembly and wipe away any
excess grease. Reassemble the
button and retry the system.
F. Air hose is damaged. F. Replace the air hose.
G. Motor/pump does not work. G. Rebuild or replace motor/pump.
2. Motor starts, not all jets
are functioning.
A. Jet is closed. A. Rotate jet trim ring
counterclockwise to open.
B. Jet is not installed correctly. B. Reinstall jet; check for O-ring
damage.
C. Jets are blocked. C. Remove blockage.
3. Footbath stops
automatically before 18
minutes.
A. The GFCI trips. A. Identify source of fault, and
correct.
B. Suction is 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.
4. Noisy operation. A. The pump banding straps have
not been cut.
A. Using tin snips, cut the pump
banding straps.
1063564-2-D 16 Kohler Co.

1063564-2-D

1063564-2-D

1063564-2-D

USA: 1-800-4-KOHLER
Canada: 1-800-964-5590
México: 001-877-680-1310
kohler.com
©2007 Kohler Co.
1063564-2-D