Kohler K-2972 Assembly instructions

Installation and Care Guide
Thermostatic Mixing Valve
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-2972, K-2975 K-2973, K-2976
1205551-2-C

IMPORTANT INSTRUCTIONS
READ AND SAVE FOR THE
CONSUMER
WARNING: Risk of scalding or other severe injury.
CAUTION: Risk of scalding hazard. This device has been
calibrated at the factory to ensure a safe maximum water
temperature. Any variance in settings or water inlet
conditions from those used during factory calibration may
raise the discharge temperature above the safe limit, and may
present a scalding hazard.
•Before completing installation, the installer must set the
maximum water temperature setting of this valve to minimize the
risks associated with scalding hazards according to ASTM F 444.
The installer is responsible for adjusting the maximum water
temperature of this valve according to instructions.
This valve meets or exceeds ASME A112.18.1/CSA B125.1 and ASSE
1016/ASME A112.18.1016/CSA B125.16.
If you do not understand any of the temperature adjustment
instructions in this document, in the United States please contact our
Customer Care Center at 1-800-4KOHLER. Outside the U.S., please
contact your distributor.
IMPORTANT NOTICE: Please fill in the blanks on the valve label and
below, in the NOTICE TO HOMEOWNERS box. Retain this guide for
future reference.
•The valve is calibrated to 104°F (40°C) at the first stop position,
and the maximum temperature limit stop is positioned so the
outlet water temperature does not exceed 120°F (49°C).
•Factory calibrated inlet conditions are:
Hot and cold water pressure = 43.5 psi (300 kPa)
Hot water supply temperature = 149°F (65°C)
Cold water supply temperature = 59°F (15°C)
•If inlet conditions differ from those used during factory
calibration, it may be necessary to re-calibrate the valve after
installation. The installer must check the mixed flow
temperature after installation, and adjust the valve as needed
according to the instructions.
1205551-2-C 2 Kohler Co.

IMPORTANT INSTRUCTIONS (cont.)
NOTICE TO HOMEOWNERS! This device has been preset by
_______________________ of _______________________________ to
ensure a safe maximum temperature. Any change in the setting may
raise the discharge temperature above the limit considered safe, and
lead to scalds.
Date: ______________
Tools and Materials
Before You Begin
WARNING: Risk of scalding. High water temperature can
cause severe burns. Set the water temperature at or below
120°F (49°C) following the adjustment procedure.
WARNING: Risk of scalding or other severe injury. Before
completing installation, the installer must set the maximum
water temperature setting of this valve to minimize the risks
associated with scalding hazards according to ASTM F 444.
CAUTION: Risk of personal injury. If the water
temperature is set too high, scalding will occur. The water
temperature should never be set above 120°F (49°C).
CAUTION: Risk of scalding. This device has been calibrated
at the factory to ensure a safe maximum water temperature.
Any variance in settings or water inlet conditions from those
used during factory calibration may raise the discharge
Thermometer
Solder
Hacksaw or
Tubing Cutter
10 mm
Hex Wrench
Propane
Torch
Adjustable
Wrench
Thread
Sealant
Assorted
Screwdrivers
Strap Wrench
Wrench and
1/2" (13 mm)
Hex Socket
Pipe
Wrench
Kohler Co. 3 1205551-2-C

Before You Begin (cont.)
temperature above the safe limit, and may present a scalding
hazard. Responsibility for installation and adjustment of this
device in accordance with these instructions lies with the
installer.
NOTICE: Risk of product damage. This valve contains plastic and
rubber components. Do not sweat or braze directly to the valve
body. Do not apply excessive heat to the valve body when you
make solder connections. Do not apply flux or acids directly to the
valve, as damage to the seals, plastic components, and trim finish
may result.
NOTICE: Risk of product damage. Do not apply petroleum-based
lubricants to the valve components, as damage may result.
NOTICE: Risk of product damage. Inlet and outlet threaded joint
connections should be made with plumbers PTFE tape or liquid
sealant. Oil-based, non-setting compounds should not be used.
NOTICE: Do not force the handle in any direction. Forcing the
handle will damage the valve.
Observe all local plumbing and building codes.
Shut off the water supply.
Inspect the supply piping for damage. Replace as necessary.
The bottom port of the thermostatic mixing valve is intended for
use as a bath filler only. If a bath spout is not used with this
product, cap the bottom port.
The K-2972 and K-2975 thermostatic mixing valves do not contain
an integral volume control/shut-off valve. You must install a
separate volume control/shut-off valve (K-2974 or K-2977)
downstream of any used valve outlet.
The K-2973 and K-2976 thermostatic mixing valves contain a
single volume control/shut-off valve for controlling the water
flow through the shower outlet. When plumbing to the valve’s
bath outlet, you must install a separate volume control shut-off
valve (K-2974 or K-2977) downstream from the bath outlet.
1205551-2-C 4 Kohler Co.

Before You Begin (cont.)
The thermostatic mixing valves do not have an integral aspirator.
For installations that use a bath diverter spout, you must install a
twin ell (K-9663) with integral aspirator between the valve and
the bath spout. If these thermostatic mixing valves are installed
without an aspirator, it will cause water to flow from the shower
and bath spout at the same time.
Determine the correct drain size and capacity for your
installation. If two thermostatic mixing valves are used together,
water volumes between 18 and 30 gal/min (60 and 114 l/min) or
more are possible, depending upon the water supply pressure.
Determine the correct water heater size and capacity for your
installation. A typical shower installation uses an approximate
mix of 75% hot water and 25% cold. A custom shower application
using three 2.5 gal/min (9.5 l/min) showerheads can use about 45
gallons (170 liters) of hot water in 8 minutes. Choose a water
heater large enough for your installation.
The valve is calibrated to 104°F (40°C) at the first stop position.
The maximum temperature limit stop is positioned so the outlet
water temperature does not exceed 120°F (49°C).
The factory calibrated pressure for hot and cold water inlets is
43.5 psi (300 kPa). The factory calibrated hot water supply
temperature is 149°F (65°C) and the cold water supply
temperature is 59°F (15°C).
If the inlet conditions differ from those used during factory
calibration, it may be necessary to re-calibrate the valve after
installation. The installer must check the mixed flow
temperature after installation and adjust the valve as needed
according to the instructions.
If possible, flush all piping thoroughly before installing the valves
to prevent early clogging of filter screens.
Kohler Co. 5 1205551-2-C

K-2972 - 1/2″Valve Roughing-In
1/2" NPT
Shower Outlet
1/2" NPT
Hot Inlet
1-1/8"
(29 mm)
1-7/16"
(37 mm)
2-1/16"
(52 mm) 3-7/8"
(98 mm)
3-3/4" (95 mm)
2-7/16"
(62 mm)
Min
Finished Wall
Max
Finished Wall
1-3/16" (30 mm) 4-5/8" (117 mm)
1/2"
(13 mm)
1/2" NPT
Cold Inlet
Stop
2-5/16"
(59 mm)
4-5/8" (117 mm)
3-1/2" (89 mm)
2-1/16"
(52 mm)
1205551-2-C 6 Kohler Co.

K-2973 - 1/2″Valve Roughing-In
Min
Finished Wall
Max
Finished Wall
2-7/16"
(62 mm) 3-3/4" (95 mm)
3-1/2" (89 mm)
1/2"
(13 mm)
4-5/8" (117 mm)
4-5/8" (117 mm)
1-3/16" (30 mm)
6-3/8"
(162 mm) 3-1/8"
(79 mm) 1-7/16"
(37 mm)
1/2" NPT
Cold Inlet
1/2" NPT
Hot Inlet
1/2" NPT
Shower Outlet
Stop
1-3/16" (30 mm)
2-5/16"
(59 mm)
2-1/16"
(52 mm)
Kohler Co. 7 1205551-2-C

K-2975 - 3/4″Valve Roughing-In
1/2"
(13 mm)
3-1/2" (89 mm)
4-5/8" (117 mm)
1-3/16" (30 mm)
Max
Finished Wall
Min
Finished Wall
2-7/16"
(62 mm)
3-3/4" (95 mm)
3/4" NPT
Bath Outlet Stop
3/4" NPT
Cold Inlet
4-7/16"
(113 mm)
2-1/16"
(52 mm) 1-7/16"
(37 mm)
1-1/8"
(29 mm)
3/4" NPT
Hot Inlet
3/4" NPT
Shower Outlet 2-1/16"
(52 mm)
2-3/8" (60 mm)
4-13/16" (122 mm)
1205551-2-C 8 Kohler Co.

K-2976 - 3/4″Valve Roughing-In
1-3/16" (30 mm) 4-5/8" (117 mm)
1/2"
(13 mm)
3-1/2" (89 mm)
3-3/4" (95 mm)
2-7/16" (62 mm)
Min
Finished Wall
Max
Finished Wall
2-3/8"
(60 mm)
1-3/4"
(44 mm) Stop
3/4" NPT
Shower Outlet
3/4" NPT
Hot Inlet
3/4" NPT
Cold Inlet
3/4" NPT
Bath Outlet
1-7/16"
(37 mm)
3-3/16"
(81 mm)
6-15/16"
(176 mm)
2-1/16"
(52 mm)
4-13/16" (122 mm)
Kohler Co. 9 1205551-2-C

1. Install the Support Framing
IMPORTANT! Make sure the valve is mounted at the correct depth
so it will be properly positioned when the finished wall is installed.
NOTE: Shower only configuration is shown. Adjust the support as
needed for other configurations.
NOTE: Install a backer board behind the valve for installations on
2x6 studding only.
NOTE: A backer board may not fit behind the valve for installations
on 2x4 studding. Support the pipes directly above and/or below the
valve. This will also provide support for the valve.
NOTE: When installing the K-2972 or K-2973 valve, use 1/2″
nominal copper tubing and fittings throughout this installation.
Smaller diameter piping upstream or downstream of the valve will
reduce performance of the valve.
2x4
4-1/4" (108 mm) Max2-15/16" (75 mm) Min
Plaster Guard
Thick WallThin Wall
2x6
Finished
Wall Finished Wall
2-7/16"
(62 mm)
3-3/4" (95 mm)
1205551-2-C 10 Kohler Co.

Install the Support Framing (cont.)
NOTE: When installing the K-2975 or K-2976 valve, use 3/4″
nominal copper tubing and fittings throughout this installation.
Smaller diameter piping upstream or downstream of the valve will
reduce performance of the valve.
Determine the desired location for the valve according to the
roughing-in information, and construct suitable stud and support
framing for your configuration and valve.
If the finished wall is drywall, 1/2″(13 mm) drywall or thicker
should be used or the finished wall will not be strong enough.
Determine the finished wall thickness. The finished wall should
not extend beyond the outside edge of the plaster guard. The
valve can be mounted with the plaster guard flush with the
finished wall for maximum wall thickness. If the plaster guard is
recessed, the finished wall is too thick. Refer to the diagram
above.
Install water hammer arrestors in the hot and cold water supply
lines.
Determine the desired location for the valve according to the
roughing-in information, and construct suitable stud and support
framing.
Kohler Co. 11 1205551-2-C

2. Install the Valve
NOTICE: Risk of product damage. This valve contains plastic and
rubber components. Do not sweat or braze directly to the valve
body. Do not apply excessive heat to the valve body when you
make solder connections. Do not apply flux or acids directly to the
valve, as damage to the seals, plastic components, and trim finish
may result.
NOTICE: Risk of product damage. Do not apply petroleum-based
lubricants to the valve components, as damage may result.
NOTICE: Risk of product damage. Inlet and outlet threaded joint
connections should be made with plumbers PTFE tape or liquid
sealant. Oil-based, non-setting compounds should not be used.
NOTE: A plaster guard is attached to the face of the mixing valve.
Do not remove it until instructed.
Flush the hot and cold water supply lines to remove any debris.
Use thread sealant and connect the hot and cold water supply
lines to the valve inlet ports. Ensure that the corresponding water
supply lines are connected to the correct inlet ports.
Cold
Supply
Hot
Supply
To Bath Spout Volume Control
To Showerhead
For finished wall thicknesses
less than 3/16" (5 mm), install
1/2" (13 mm) plywood backing
behind cutout.
Cap outlet if not used.
K-2976-KS
Shown
1205551-2-C 12 Kohler Co.

Install the Valve (cont.)
NOTE: If the existing hot and cold plumbing makes this
configuration inconvenient or if it is advantageous to reverse the hot
and cold ports (such as back-to-back installations), see the ″Reverse
the Inlet Supplies″section.
For K-2973 and K-2976 valves, make certain that the integral
volume control/shut-off valve portion of the assembly is on top
when installed.
Connect the water outlet lines to the valve ports. Plug any
unused outlet port.
IMPORTANT! Secure the piping to the framing.
NOTE: When using the plaster guard to trace the cut-out, the tick
marks located outside of the guard will assist you in identifying the
spline centers.
Use the plaster guard to determine the depth of the valve in the
wall, and to trace the cut-out line in the wall material.
NOTE: The finished wall must be within the MIN-MAX depth
shown on trim adapters 1, 2, and 3 of the plaster guard.
Turn on the water supply lines to the valves.
Run water through the mixing valve, all showers, and the spout.
Remove the plaster guard to access and inspect the valve.
Kohler Co. 13 1205551-2-C

3. Reverse the Inlet Supplies
IMPORTANT! The steps in this section are optional. Only perform
these steps when the hot and cold inlet supplies are reversed.
The inlet connections are indicated on the inlet ports of the
thermostatic valve assembly. Left is HOT and right is COLD. If this
configuration is not suitable for your installation, the cartridge may
be rotated 180° to reverse the hot and cold inlet ports.
NOTE: DO NOT pull the removal clip from the cartridge assembly
at any time during this procedure. The retaining clip helps hold the
temperature limit stop and detent components in place and reduces
or eliminates the need for temperature adjustments.
With the valve already installed and pressurized:
Turn both integral supply stops 90° counterclockwise until they
contact the stop bracket.
Turn the volume control valve stem (not shown) fully clockwise
to release the pressure.
Slowly loosen the head nut, turning it counterclockwise. This will
begin to draw the cartridge out of the valve body.
Cartridge
Remove the cartridge and rotate 180˚.
Seal
Seal
Head Nut
Supply Stops
Tab
1205551-2-C 14 Kohler Co.

Reverse the Inlet Supplies (cont.)
NOTE: Some water may be released. Use a bucket and towels to
contain the water.
Pull the head nut with the cartridge out of the valve body.
NOTE: Two seals may fall out when the cartridge is removed. Set
the seals aside.
Rotate the cartridge 180°.
Verify the cold cartridge inlet is on the left when the valve stem
adapter is facing you.
NOTE: The hot and cold cartridge inlets are identified on the top
and sides of the cartridge tabs. The tabs are labeled ″H″and ″C″to
identify hot and cold.
TIP: Rotating the cartridge back and forth or installing with a
push-pull motion will reduce the possibility of pinching the side
seals.
Reinstall the seals onto each side of the cartridge.
Carefully push the cartridge back into the valve body. Make sure
both cartridge tabs are properly seated inside the cartridge slots
of the valve body.
Handtighten the head nut onto the valve body. Do not
overtighten.
Return the integral supply stops back to their original position.
Make note of reversed inlet supplies on the valve for future
servicing.
Kohler Co. 15 1205551-2-C

Integral Supply Stop Operation
NOTE: Use a socket wrench with 1/2″(13 mm) socket to adjust the
stops.
Turn Off the Stops
Use a socket wrench to turn the integral stops 90°
counterclockwise to close both the hot and cold water inlet
supplies.
NOTE: If the inner body turns, but the outer ring does not turn,
firmly tighten (clockwise) the integral stop. Then rotate
counterclockwise. The outer ring should then turn with the integral
stop.
NOTE: If the outer ring still does not turn, slide the locking bar up
by loosening the screw. Free the integral stops by turning them
clockwise and then turn them back to their original position. Slide
the locking bar back in place and secure with the screw.
Confirm the stops are closed using the diagram above.
Turn the volume control counterclockwise to release excess water
(not shown).
Turn integral supply stops 90˚
for OPEN/CLOSE.
Integral
Supply Stops
Supplies Closed
Supplies Open
Locking Bar
1205551-2-C 16 Kohler Co.

Integral Supply Stop Operation (cont.)
The cartridge or check valves may now be removed for servicing
or replacement.
NOTE: Keep a rag handy to catch excess water that will gradually
drain when the valve cartridge is removed.
Kohler Co. 17 1205551-2-C

Servicing the Filters
Remove the trim.
Close both stops following the instructions in the previous
section.
Use a socket wrench with 1/2″(13 mm) socket to remove the stop
assembly (hot is left side, cold is right side).
Remove the screen assembly by turning and pulling from the
check valve body.
Clean or replace the screen assembly as needed.
Clean or replace the check valve body as needed.
Reinstall the screen assembly to the check valve body by pushing
in and turning 90°.
Reinstall the check valve body by turning clockwise until it drives
the stop body open.
Open the supply stops and check for leaks.
Reinstall the trim.
Remove screen.
Twist.
1205551-2-C 18 Kohler Co.

Check the Temperature Setting
NOTE: The thermostatic valve cartridge is calibrated at the factory
for a shower temperature of approximately 104°F (40°C) to 105°F
(41°C) and a maximum hot temperature of 120°F (49°C).
Turn the water on.
Attach a trim handle or plaster guard (found in volume control
valve K-2974 or K-2977 or transfer valve K-728) onto the valve
spline adapter.
Turn the spline adapter fully counterclockwise so the trim handle
or plaster guard can no longer move. The spline adapter is now
in the full hot position.
Allow the water to run for several minutes to stabilize the water
supply temperatures.
Position a thermometer in the water stream to check the
temperature of the hot water.
If the water temperature exceeds 120°F (49°C) or is less than
desired, proceed to the ″Adjust the Hot Temperature Limit″
section.
Turn the trim handle or plaster guard clockwise until you hear a
click. Do not turn any further. This is the shower temperature
position.
Remove the trim handle or plaster guard from the valve spline
adapter.
Decrease Temperature
Increase Temperature
Spline
Adapter
Kohler Co. 19 1205551-2-C

Check the Temperature Setting (cont.)
Position a thermometer in the water stream to check the shower
temperature.
If the water temperature is less than 104°F (40°C) to 105°F (41°C)
or is more than desired, proceed to the ″Adjust the Shower
Temperature″section.
If both settings are correct, fill out the ″NOTICE TO
HOMEOWNERS″section in the beginning of this document.
1205551-2-C 20 Kohler Co.