Kohler Seawall K-6504 User manual

Installation Guide
Deck-Mount Bath Faucet
with Handshower
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-6504
113762-2-CD

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
Observe all local plumbing and building codes.
Shut off the main water supply.
Provide an access panel for all installations.
Carefully read this entire instruction manual before beginning the
installation; the illustrations do not show all possible
configurations.
These installations lead up to, but do not include, the wall-mount
shower arm installation.
Carefully inspect waste and supply tubing for any sign of
damage.
Replace waste or supply tubing if necessary.
This product is designed for use with the K-868 bath, K-870
whirlpool, or K-1398 whirlpool.
Install the faucet to the bath/whirlpool before installing the
bath/whirlpool.
The transfer valve contains an integral vacuum breaker.
Assorted
Screwdrivers
• Support blocks or
straps
• Elbows, tubing or
additional plumbing
hardware
• Drill
• Scissors
• Plumbers putty
Plus:
Adjustable
Wrench 5/64" and 5/32" Hex
Wrench
Safety
Glasses
Snap Ring
Pliers SolderPropane Torch
Open End
Wrench
113762-2-CD 2 Kohler Co.

Before You Begin (cont.)
The deck width from the bath rim must be a minimum of 2″(5.1
cm) to allow clearance for the faucet fittings.
Kohler Co. recommends hard-drawn tubing (type M, K, or L)
from the valves to the transfer valve to the spout.
Kohler Co. recommends soldering all connections from the
transfer valve to the spout as well as from the transfer valve to
the hot and cold valves.
To avoid potential leakage below the rim, do not use flexible hose
connections.
Use 1/2″nominal tubing (5/8″OD) for the outlets and 3/4″
nominal tubing (7/8″OD) for the inlets.
Install water hammer arresters in the supply line.
Kohler Co. reserves the right to make revisions in the design of
products without notice, as specified in the Price Book.
Kohler Co. 3 113762-2-CD

1. Component Layout
Verify the location of the components and the orientation of all
ports.
Determine the location and orientation of the transfer valve. The
location of the bath spout, handshower, and the optional auxiliary
shower will affect the piping and connectors needed.
Allow clearance for valve outlets, handles, bath spout, and
handshower hoses.
You can extend the distance between the transfer valve and the
braided hose connection with 1/2″copper piping below the rim
of the bath/whirlpool, but it may not be safe or practical. A long
run of piping will mean a long run of room-temperature standing
water when the handshower is first activated for use.
NOTE: The distance between the transfer valve and the braided
hose connection with 1/2″copper piping below the rim of the
bath/whirlpool, but it may not be safe or practical. A long run of
piping will mean a long run of room-temperature standing water
when the handshower is first activated for use.
Secure long runs of piping to the underside of the deck or rim. If
the piping cannot be secured at a point near the transfer valve,
secure the piping from underneath with lumber or other suitable
support.
Hose Connection
Braided Hose
Decorative Hose
113762-2-CD 4 Kohler Co.

2. Preparation
For K-1398 Whirlpool Only:
CAUTION: Risk of personal injury. Wear safety goggles when
marking, prick punching, and drilling holes.
NOTE: Tape the templates into place to simplify procedure.
Position Template #1 on the bath rim (drain side) as shown.
Mark and drill two 1-1/2″(3.8 cm) holes for the valves.
Position Template #2 on the bath rim (drain side) as shown.
Mark and drill a 2″(5.1 cm) hole for the transfer valves.
Mark and drill a 1-1/4″(3.2 cm) hole for the handshower hose
guide.
Mark the centerline of the bath on the bath wall opposite the
drain side.
NOTE: Do not locate the template lower than 3″(7.6 cm) down from
the bath bench.
Position Template #3 (metal) on the bath rim (drain side) as
shown.
Mark the five hole locations on the bath wall.
Drill 1/8″(3 mm) pilot holes at each of the five locations.
At the center pilot hole, drill a 1-3/8″(3.5 cm) hole for the spout
sleeve.
Drain
Template #1
Template #2
Template #3 (Metal)
3" (7.6 cm)
Fastener Holes (4 Required)
Spout Sleeve Hole
Bath Bench
Centerline of
Bath Fitting
Kohler Co. 5 113762-2-CD

Preparation (cont.)
Refer to the hardware assembly kit to determine if your fastener
type is rubber or steel.
For rubber fasteners: Drill 1/2″(1.3 cm) holes at each of the
remaining four pilot hole locations.
For steel fasteners: Drill 3/8″(1 cm) holes at each of the
remaining four pilot hole locations.
113762-2-CD 6 Kohler Co.

3. Verify the Spout Tube Fit
Align the spout tube and spout sleeve with the pilot holes on the
bath wall.
Place the gasket over the spout sleeve.
Temporarily place the sleeve through the center hole on the bath
wall.
Loosely thread the retaining nut onto the sleeve.
NOTE: K-868 and K-870 have the fasteners pre-installed into the
bath wall.
For K-1398 Whirlpool Only:
Thread the rubber fasteners (supplied in the hardware kit) to the
tube assembly or install steel fasteners into the bath wall.
For All Installations:
Verify the alignment of the spout tube with the holes in the bath
wall.
Place the spout tube back into the carton for protection.
Prior to soldering, remove the fasteners and the spout sleeve.
Bath Rim
Gasket
Retaining Nut
Fasteners
Spout Tube
Sleeve
Kohler Co. 7 113762-2-CD

4. Install the Spout Sleeve
Determine which coupling will be required.
Verify adequate clearance away from the bath wall and framing
to allow for soldering the final connection after the
bath/whirlpool is moved into place.
Solder the coupling to the sleeve.
Allow the assembly to cool before installing it to the bath wall.
After the assembly has cooled, place the gasket over the sleeve
assembly.
Apply a bead of sealant to the back of the sleeve and around the
back of the hole in the bath wall.
Slide the sleeve assembly through the bath wall.
Slide the rubber and fiber washers over the sleeve.
Secure the assembly to the bath wall by threading the retaining
nut onto the sleeve.
Sleeve
Coupling
Back of BathWall
Sleeve
Retaining Nut
Fiber Washer
Rubber Washer
113762-2-CD 8 Kohler Co.

5. Install the Hose Guide
Deck-Mount Installations
From the top of the finished deck, drill a 1-1/4″(3.2 cm)
mounting hole.
For All Installations
Slide the washer down the shank until it is flush against the
finished deck.
Thread the escutcheon onto the shank until it is flush against the
finished deck.
From the top of the bath or finished deck, insert the shank into
the mounting hole of the finished deck.
From the underside of the bath, thread the shank nut onto the
shank until it is flush against the finished deck.
Secure the shank nut to the finished deck. Do not overtighten.
Hose Guide
Escutcheon
Washer
Shank Nut
Shank
Kohler Co. 9 113762-2-CD

6. Install the Valve Handle
Thread the mounting nut with the flange side up onto each
″Cold″and ″Hot″valve handle.
Slide the fiber washer and the rubber washer onto each ″Cold″
and ″Hot″valve handle and onto the mounting nut.
NOTE: Valve handles that are marked ″Cold″must always be
installed into the mounting hole on the right as viewed from the
front of the bath.
From the underside of the bath, insert the valve handles up into
their respective mounting holes.
Thread a collar onto each valve body with the flange side facing
upward. Thread the collar down until the distance between the
deck/rim to the top of the valve stem is 1-13/16″(4.6 cm).
Thread a mounting nut up to the underside of the deck/rim to
secure each valve in place.
Repeat the process for the second valve.
Valve Body
Mounting Nut
Fiber Washer
Rubber Washer
1-13/16"
(4.6 cm)
Collar Mounting Nut
113762-2-CD 10 Kohler Co.

7. Convert to Two-Way Valve
CAUTION: Risk of property damage. For a two-way
configuration only: the auxiliary outlet must be capped off to
prevent possible leakage out of the unused auxiliary outlet.
NOTE: The valve is pre-assembled for use as a three-way transfer
valve.
Remove the plated nut.
Carefully pull the cartridge from the brass body.
NOTE: Use care to prevent the cartridge seals and O-rings from
falling off, or becoming dirty or damaged.
Line up the transfer tube stop with the slot in the gray collar.
Use a flat-blade screwdriver to carefully pry the two locking tabs
loose from the transfer tube.
Remove and discard the gray three-way stop collar.
Verify the hole in the transfer tube lines up with the large port in
the cartridge.
Align the black collar on the transfer tube with the collar tab lines
on the large port of the cartridge.
Snap the collar in place to ensure both locking tabs are fully
engaged.
Inspect the seals and O-rings for damage and proper fit. Make
any adjustments if needed.
Grey Collar Slot
Plated Nut
Cartridge
Brass Body
Cap
Notch
Collar Tab
Collar Tab
Locking Tab
Remove and
discard grey
3-way stop
collar.
Transfer tube
hole must
line up with
large port.
Inspect seals
and o-rings.
Auxiliary
Outlet
Transfer
Tube Stop
Black 2-way Collar
Kohler Co. 11 113762-2-CD

Convert to Two-Way Valve (cont.)
Carefully work the cartridge into the brass body until the collar
tab fits into the notch in the brass body.
Thread the plated nut onto the brass body and hand tighten.
113762-2-CD 12 Kohler Co.

8. Install the Transfer Valve
CAUTION: Risk of product damage. Excessive heat will damage
the internal plastic components.
IMPORTANT! Do not apply excessive heat while soldering. Direct
the torch flame away from the brass body.
IMPORTANT! Only apply direct heat to the connectors and
extensions.
IMPORTANT! If there is limited access to the solder connections or
if any other risk of excessive heat being applied to the brass body
exists, remove the cartridge prior to soldering. If you remove the
cartridge, protect the seals and O-rings from becoming dirty, being
damaged, or misaligned.
IMPORTANT! If the transfer valve is to be used in a two-way
configuration, solder a cap to the auxiliary outlet.
Solder the inlet and outlet connectors and extensions.
Remove the plaster guard and plated nut from the valve. Do not
remove the cartridge.
Remove the collar from the brass body.
Thread the mounting nut down onto the brass body.
Slide the washer onto the brass body until it is flush against the
mounting nut.
Cast Iron Baths
Other Baths
Mounting Nut
Plaster Guard
Cartridge
Auxiliary Shower Outlet Port
Cap
Bath Outlet Port
Plated Nut
Brass Body
Collar with Flange Down
Washer
Handshower Outlet Port
1/2" Male Adapter
Mixed Water Inlet Supply Port
Collar with
Flange Up
Kohler Co. 13 113762-2-CD

Install the Transfer Valve (cont.)
For cast iron baths: Thread the collar partially onto the brass
body with the flange down.
For all other baths: Thread the collar partially onto the brass
body with the flange up.
Hand tighten the plated nut onto the brass body.
Reinstall the plaster guard.
Position the collar to create a gap 1/8″(3 mm) to 9/16″(1.4 cm)
between the finished deck and the bottom of the plaster guard.
Securely tighten the mounting nut until it is flush against the
finished deck.
Dry fit all the piping and connectors.
Solder the remaining piping and connectors.
113762-2-CD 14 Kohler Co.

9. Install the Bath/Whirlpool
NOTE: If the installation includes a wall-mount shower: Before the
bath/whirlpool is installed, plumb in the shower inlet to allow for
the connection to the transfer valve.
Install the wall shower (if applicable) before installing the
whirlpool bath.
Dry fit all the plumbing for the shower connections before
soldering.
Cover the escutcheons, hose guide, and transfer valve.
Install the bath/whirlpool according to the instructions packed
with the product.
NOTE: Do not install the finished wall until the final connections are
made and the installation tested.
10. Solder the Connections
CAUTION: Risk of product damage. Protect the backside of the
bath from excessive heat when soldering. Damage caused by
excessive heat is not covered by the warranty.
Dry fit all the plumbing connections before soldering.
Solder all the connections.
Wall Shower
Hot Valve
Transfer Valve
Cold Valve
Handshower
Transfer Valve
Kohler Co. 15 113762-2-CD

11. Complete the Valve Installation
Remove the plaster guard.
Turn on the main water supply.
Confirm proper operating of the transfer valve and associated
fittings.
Carefully inspect the entire installation for leakage and proper
operation. Adjustment as needed.
Hand tighten the plated nut to the brass body.
NOTE: If the trim will not be installed immediately, reinstall the
plaster guard.
Cast Iron Baths
Other Baths
Mounting Nut
Plaster Guard
Cartridge
Auxiliary Shower Outlet Port
Cap
Bath Outlet Port
Plated Nut
Brass Body
Collar with Flange Down
Washer
Handshower Outlet Port
1/2" Male Adapter
Mixed Water Inlet Supply Port
Collar with
Flange Up
113762-2-CD 16 Kohler Co.

12. Install the Handles
Turn the transfer valve to the bath fill position. For a two-way
valve, turn the transfer valve fully clockwise. For a three-way
configuration, turn the transfer valve to the center position.
Apply plumbers putty or other sealant around the escutcheon
flange according to the manufacturer’s instructions.
Position the escutcheon loosely on the valve. Ensure the three
dots on the escutcheon will be clearly visible once installed. The
center dot indicated the bath fill position.
Temporarily position the knob on the transfer valve to confirm
the alignment of the dots.
Remove the knob.
Firmly press the escutcheon into place.
Remove any excess plumbers putty or sealant.
Verify that the two trim rings and the O-ring are still in place on
the knob.
Reinstall the knob and secure it with the screw.
Snap the cap onto the knob.
Align three dots (center dot
should indicate bath fill).
Valve
Pin
Knob
Grooves
Trim Rings
O-Rings Screw
Cap
Confirm dot alignment.
Escutcheon
Kohler Co. 17 113762-2-CD

13. Install the Handshower
From the top of the bath or finished deck, insert the smaller end
of the interlock hose down into the hose guide and through the
mounting hole.
From the underside of the bath or finished deck, insert one
washer into the flexible hose.
Thread the flexible hose into the high pressure hose.
Insert one washer into the other end of the high pressure hose.
Connect the high pressure hose onto a vacuum breaker (if
installed), or onto the appropriate water source.
Run cold and hot water through the handshower hose to flush
out dirt and debris.
Check for leaks.
Turn the cold and hot water valves off.
For an elbow installation:
Insert the washer into the bottom of the elbow assembly.
Thread the handshower onto the elbow assembly.
Thread the handshower onto the elbow assembly.
For an upright installation:
Insert the screen washer into the end of the handshower.
Screen/
Washer
Handshower
Handshower
Washer
Washer
Water Source High Pressure Hose
Washer
Interlock Hose
Interlock Hose
Washer
Elbow Assembly
Screen/Washer
Handshower
Elbow InstallationUpright Installation
113762-2-CD 18 Kohler Co.

Install the Handshower (cont.)
Thread the handshower onto the handshower hose.
To avoid kinking, remove any twists or loops in the hose.
Kohler Co. 19 113762-2-CD

14. Install the Valve Handles
Position a gasket over each valve body.
Thread an escutcheon onto each valve body.
Fit a spline adapter halfway onto each valve stem.
Partially install each skirt assembly onto a spline adapter.
Check the skirt assembly alignment. If further alignment is
needed, reposition the spline adapter until the skirt assembly is
properly aligned.
Remove the outer shell from each skirt assembly.
Fasten each skirt to a valve with a screw.
Place the inset onto the top of the skirt assembly.
Thread the outer shell onto each skirt.
Outer Shell
Spline Adapter
Inset
Inset Holder
Screw
Skirt
Gasket
Escutcheon
113762-2-CD 20 Kohler Co.