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Guillen's Enterprises, Inc.

Since 1973Kohler authorized genuine service parts distributor

11040 West Flagler Street. Miami, FL 33174 USA

Phone (800) 222-7855 (24/7)

www.guillens.com

Guillen's Enterprises, Inc. - Since 1973 - a Kohler authorized genuine service parts distributor 11040 West Flagler Street. Miami, FL 33174 USA (800) 222-7855 (24/7)

Revised: 20120315

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KOHLER

KOHLER WHIRLPOOL ~~Wll~rn; WiU~If{I1l1J~IL

With Electronic TImer

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SECTION 1

SECTION 2

SECTION 3

SECTION 4

SECTION 5

This manual covers service and maintenance procedures for the following Kohler Whirlpool models:

• Super Bath™ Whirlpool K-1422 • Infinity BathTM Whirlpool K-1482, K-1484 • CaribbeanT" Whirlpool K-802 • Steeping Bath™ Whirlpool K-792 • GuardianTM Whirlpool K-783, K-784 • Barbados™ Whirlpool K-1409, K-1410 • Pristme'M Whirlpool K-772

TABLE OF CONTENTS

GENERAL INFORMATION INTRODUCTION ... WARNINGS AND PRECAUTIONS. SERIAL NUMBER LOCATION SERVICE AND MAINTENANCE. COMPONENT LOCATIONS .....

GENERAL SYSTEM DESCRIPTION THEORY OF OPERATION ......... WATER FLOW ..................... TROUBLESHOOTING .... ......... COMPONENT IDENTIFICATION LIST.

TIMER THEORY OF OPERATION ..... SERVICING THE TIMER WHIRLPOOL TIMER CONVERSION. COMPONENT IDENTIFICATION LIST ..

POWER PANEL THEORY OF OPERATION. SERVICING THE POWER PANEL COMPONENT IDENTIFICATION LIST.

WATER LEVEL CONTROL THEORY OF OPERATION SERVICING THE WATER LEVEL

CONTROL ............. Breather Valve ....................... Float Chamber .........

COMPONENT IDENTIFICATION LIST.

2 3

4 4 5 7

8 8 9

10

11 11 12

13

13 13 14 14

SECTION 6 MOTOR AND PUMP THEORY OF OPERATION ..... 15 SERVICING THE MOTOR AND PUMP.. 15 ITT MARLOW 60041, 60097 AND 60388-M

MOTOR AND PUMP 15 COMPONENT IDENTIFICATION LIST ... 16 ITT MARLOW 60186, 60187, 60478, 60479,

60660-M, 60661-M, 60457, 60501. 60662-M AND 60663-M MOTOR AND PUMP .... 16

COMPONENT IDENTIFICATION LIST.. 17 HAYWARD 60660-H AND 60661-H

MOTOR AND PUMP................ 17 COMPONENT IDENTIFICATION LIST. 18

SECTION 7 TRIM KITS SERVICING THE TRIM KITS ........... 19

Air Control Assembly ........ 19 Adjustable Jets.. 19 Suction Inlet ... . .... 20

COMPONENT IDENTifiCATION LIST ... 20

SECTION 8 INFINITY BATH FAUCET FITTINGS COMPONENT IDENTIFICATION LIST ... 21

SECTION 9 OLD STYLE TIMERS AND POWER PANEL ... . ............... 23

SECTION 1- GENERAL INFORMATION

INTRODUCTION

The purpose of this manual is threefold: to provide familiarization with Kohler Whirlpool Bath operation: to provide detailed maintenance and functional check­out instructions; and to provide comprehensive re­placement and service parts Information.

This manual contains a general system description, functional checkout procedures and an identification of all major components. Theory of operation and repair information for the individual components are included in their respective sections.

WARNINGS AND PRECAUTIONS

1. Kohler Company does not assume responsibility for warranty repairs performed by anyone other than an Authorized Service Representative (ASR).

2. When servicing the control panel, motor and pump or any portion of the system where high voltages may be encountered, ensure power to the Whirlpool Bath is OFF.

3. All electrical work shall be performed by a qualified electrician or ASA.

4. Pump motor may operate at high temperatures; avoid coming in contact with motor shell while pump motor is operating or shortly after shut­down.

5. After servicing the Whirlpool Bath, always re­install all safety devices as originally found prior to repair or service.

6. Local electrical codes may require use of a Ground Fault Circuit Interrupter (GFCI) on circuits sup­plying powerto the Whirlpool Bath. Kohler Com­pany recommends the use of a GFCI on all installations.

7. All finish materials - enamels, acrylic, plating, etc. - can easily be damaged. Do NOT stand or place tools in Whirlpool Bath. Kohler Company will not be held responsible for damage to finish caused during repair.

8. Modifications, additions or deletions shall not be made to Kohler Whirlpool Baths.

9. Instructions, drawings and schematics contained in this manual represent information available at time of printing. Although every attempt has been made to keep them as up-to-date as possible, Kohler Company reserves the right to implement product changes without prior notice.

10. Kohler Company will not assume responsibility for product performance or safety where repJace-

ment components or parts other than Genuine Kohler Replacement Parts or authorized alternates are used.

11. Kohler Company recommends all gaskets, seals and O-rings be replaced if removed during service or inspection procedures.

SERIAL NUMBER LOCATION

The serial number is a 10-character code provided on each Whirlpool Bath to establish a uniform method of permanently marking each unit. The serial number is located on the Whirlpool Bath pipe harness return line directly above the power panel so it is viSible after installation with the access panel removed.

All warranty reports and invoices must include the serial number.

The serial number indicates the following; • Manufacturing facility. • The decade in which it was manufactured. • The year of manufacture. • The month of manufacture. • In-plant identification.

Manufacturing Facility Code - The first character (alpha) in the string of numbers as listed below.

Manufacturing Code Pre Code Post Facility Jan. 1, 1983 Jan. 1, 1983

Brownwood C T Richmond R R Spartanburg B S Toledo A A Wisconsin 0 W

Decade When Manufactured - The second character (numeric) in the string of numbers.

Examples; 7 for the 70's, 8 for the 80's, etc.

Year Of Manufacture - The third character (numeric) in the string of numbers.

Examples: 8 for 78, 1 for 81, 2 for 82, etc.

Month Of Manufacture - The fourth character (alpha) in the string of numbers as listed below.

Month Code Month Code

January A July G February B August H March C September I April 0 October J May E November K June F December L

Serial Number

, ,

-,-TI ) __ :.7" LlJ -\l}

Figure 1-1. Serial Number Location

In-Plant Identification - The fifth through eighth characters (numeric) in the string of numbers are used for in-plant identification.

Whirlpool Designate Code - Follows the eighth character of the string as "IX."

Examples:

• Manufactured pre January 1, 1983. D78A0006/X.

- D. Wisconsin manufacturing facility. - 7. Manufactured in the 70's. - 8. Manufactured in 1978. - A. Manufactured in January.

• Manufactured post January 1,1983. W83B0006/X.

- W. Wisconsin manufacturing facility. - 8. Manufactured in the 80's. - 3. Manufactured in 1983. - B. Manufactured in February.

NOTE: All Whirlpool serial numbers manufactured priorto February, 1980 included a "K" prefix indicating Wisconsin as the manufacturing facility.

2

SERVICE AND MAINTENANCE

Kohler Whirlpool Baths require a minimum of mainte­nance for trouble-free operation. Removal and re­placement procedures, as well as repair techniques for the various components of the Whirlpool Bath, are provided in the following sections of this manual.

Only commonly used tools are required to service Kohler Whirlpool Baths, however, a multimeter is required to test the electrical components of the system.

Service should be periormed by an Authorized Service Representative (ASR).

CAUTION: When servicing the power panel, motor and pump or any other portion of the system where high voltages may be present, ensure the power to the Whirlpool Bath is OFF. If voltage measurements are required, use caution.

Service and maintenance procedures described in this manual apply to all models of the Whirlpool Bath. Although component configuration may differ from model to model, operation and service are relatively the same.

COMPONENT LOCATIONS

Figure 1-2 will help you locate the different compo­nents on the various models.

, 4

5 2

,-it ..... l ~~l

3

Guardian

Caribbean Pristine

5

2

The Super Bath

1. Adjustable Jet 2. Adjustable Air Control 3. Molor and Pump

4

2 5

,

Infinity 00 Bath

-- 1 --t-=_ " . I

d, 4':"

1_2 II tt' ,

-~---

3

Steeping 8ath

3

Barbados

4. Water Suction Inlet 5. Safety Grip Handle

Figure 1-2. Component Locations

3

SECTION 2- GENERAL SYSTEM DESCRIPTION

THEORY OF OPERATION

Each electronically actuated Kohler Whirlpool consists of five basic components:

Bath

• Tub which acts as a reservoir for the water and provides a location for the whirlpool action.

• Timer which turns the Whirlpool Bath ON and OFF, and controls the length of time the Whirl­pool Bath is in operation.

• Power panel which provides electricity to drive the motor and pump.

• Water level control which inhibits Whirlpool Bath operation if there is too little water in the tub.

• Motor and pump which provide the power to move the water and create the whirlpool action.

WATERFLOW

Basic water flow for the Kohler Whirlpool Bath is depicted in Figure 2-1. Once filled with water, the Whirlpool 8ath becomes a self-contained system.

Water is drawn from the tub through the water suction inlet typically located near the bottom of the tub, pulled into the pump, and forced back out to the tub through adjustable jets located in the tub walls.

Air is asperated into the water stream at the jets and adjusted using the air controls.

This cycle continues as long as the motor and pump are operating.

4

o

Air Control

Adjustable I

Legend

D Water

D Air

Figure 2-1. Water Flow

TROUBLESHOOTING

NOTE: This troubleshooting guide is a general aid only. All electrical problems should be resolved by an authorized Kohler repair service or qualified electrician. If the problem cannot be resolved, contact the installing contractor or the local Kohler branch office.

SYMPTOMS PROBABLE CAUSES ~CO""MENDED ACTION = Pump not pumping. Low water level in tub Fill tub to proper level

(below jets).

2. Suction air leak. Tighten all clamps and fittings on suction side of pump.

2. Motor does not turn. 1. No power to motor. Check that all power switches are on. Be sure fuse or circuit breaker is properly set.

Check that time is set properly.

3. Low water flow. 1 . Suction air leak. Tighten all clamp fittings on suction side of pump.

2. Discharge jets partially closed Clean clogged jets. or clogged.

3. Orifice jet assembly missing. Install orifice. r-4. Noisy operation.

-

1. Air leak in suction line. Repair leak. Check suction pipe. Tighten clamps.

2 Restricted suction line due to Remove blockage. blockage.

3 Bad beanngs on motor. Have electrician replace motor.

5 Motor overload. 1. Motor is improperly connected. Check wir"tng diagram on motor. NOTE: Electrical work must be 2. Low voltage due to undersized Check with volt meter. Increase done by a qualified electrician wire or low voltage. size of supply wire. Report low or an authorized Kohler service supply voltage to power company. representative. Voltage at motor must be within

10% of motor nameplate voltage during operation.

6. Water leaking along pump 1. Worn pump seal. Disassemble pump and replace shaft. seal.

7. Timer display lights with set 1. Defective timer. Replace circuit board. time, but pump does not start 2. Faulty timer cable. Replace cable. when START/STOP activated.

3. Faulty re!ay. Replace relay.

8. Pump always on while power 1 Defective relay (lOW or no Replace relay. applied to system. v?~tage at rel~y input).

9. Pump running slow and erratic Low voltage to pump from high Check voltage at pump. Replace with growling noise. voltage side of relay. relay if less than line voltage.

2. Short in timer cable. Replace cable. -

10. Timer sets time and counts 1. Relay defective. Replace relay. down, but pump will not run. _. --

5

.. - -

SYMPTOMS ~.

11. Pump runs and trips GFCI breaker.

12. Whirlpool starts itself.

13. Whirlpool timer flashes "L" when START/STOP pushed.

. _-.... 14. No display/timer dead.

15, Timer LED missing legs.

~~~-

16. Whirlpool flashes "L" with tub full.

17. Whirlpool does not flash "L" with tub empty.

18. Pump runs but no whirlpool action.

6

TROUBLESHOOTING (Continued)

1.

2

3.

4.

1.

2.

3.

4.

1.

2.

3.

4.

5.

1.

2.

3.

1.

1.

2.

1

1.

2.

~-

PROBA BlE CAUSES

Bad bearing in pump.

Loose electri cal connections.

less than 5 GFCI trips at milliamperes

Ground fault in system.

Not on a sep arate circuit.

Power outag e, lightning voltage ent noise. spike, transi

Contaminant s (sawdust, metal 60347 timer board. shavings) on

Faulty relay.

Water in tub

Three-hole r

not 2" above jets.

etainer in jet wrong location.

eather.

assembly in

Air lock in br

Obstruction hole retainer

in line from three­to float control.

Failure on 60 347 printed circuit bly or in timer board assem

cable.

Face plate n ot making contact set time and with foils for

STARTiSTO P. No output 0

transformer

Timer cable damaged at

n secondary side of (6-14VDCi.

connection loose or timer prongs.

Timer circuit ry defective.

Three-hole r etainer in jet wrong location. assembly in

Water level s ensor float reversed.

Level float pi ug disconnection.

RECOMMENDED ACTION

Replace pump.

Secure all contacts.

Replace GFCI breaker.

Disconnect wires from relay. Check resistance between case and terminals. If below 100 kilohms, replace relay.

Wire electrical supply on separate circuit.

Replace 60347 printed circuit board.

Clean or replace 60347 printed circuit board.

Replace relay.

Add water.

See trim kit installation instructions.

Clean breather orifice and observe water to fill up into clear tube equal to water level in tub.

Remove cover of float control and run wire to orifice hole in jet assembly.

Disconnect float control plug from power pack. If timer still flashes "L", replace 60347 timer board. Also check control cable for nails .

~

Masonry box not flush with finished wall (see installation instructions for 60350 timer).

Replace transformer.

Secu re connection or replace 60318 timer cable.

Replace timer 60347 printed circuit board.

See trim kit installation instructions.

Invert float.

Insure connection.

~------ ~~.~ ----

Brass orifice s missing behind jet Install orifices. assembly.

Suction bloc ked. ______ -'C:'I"'e"a"r sucti ":'o"n.'-____ _

COMPONENT IDENTIFICATION LIST

5_ 1 ,

, 2 (' ~ 00

8 7

• ~

Item No. Description Quantity Item No. Description Quantity

1 Timer 1 5 Adjustable Air Control 2 2 Power Panel 1 6 Adjustable Jets 3 Water Level Control 1 7 Water Suction Inlet 1 4 Motor and Pump 1 8 Timer Cable 1 . - Depends on model

Figure 2-2. Whirlpool Bath

•

7

SECTION 3- TIMER

THEORY OF OPERATION

Power for the timer (Fi QUre5}.-1), provided by the

power panel, is between a 'I\~!!6 G VDC and can be measured across pins 1 and 5 of connector P1 with the plug connected and the system activated. The water level control is connected to the timer through pin 3 of connector P1. When the water level is too low for safe operation of the Whirlpool Bath, an "L" appears on the digital display. The water level control also prevents Whirlpool Bath operation when the water level is too low.

sw,

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White Power Red Panel

Green -

Figure 3-1. Timer Board

Whirlpool operating time is set by closing the contacts of SET TIME pushbutton SW1 The last operating time is shown on the digital display. Pressing and holding SW1 allows selection of running time, from 1 to 19 minutes. When SW1 is released, the time setting IS put into memory and controls the length of time the Whirlpool Bath will operate.

Start/Stop pushbutton SW2 turns the Whirlpool Bath ON and OFF causing the microprocessor to activate and deactivate the relay in the power panel. The Whirlpool Bath automatically turns OFF when time on the digital display runs out or if the water drops below the minimum level for safe operation.

Pushbutton SW1 must be pressed and time must be displayed before pushbutton SW2 will activate the Whirlpool Bath. The time displayed goes off after 30 minutes if the Whirlpool Bath is not turned ON. Pushbutton SW1 will not change the set time if the Whirlpool Bath is running, but will change the time when the "L" is flashing.

SERVICING THE TIMER

The timer printed circuit board is nonrepairable. Should it become defective, replace using the fol­lowing procedure (refer to Figure 3-3):

CAUTION: Before servicing the timer, ensure power to the Whirlpool Bath is OFF.

1. Loosen two setscrews on bottom of control plate.

2. Remove control plate.

Figure 3-2. Timer Schematic

B

3. Remove screws securing timer circuit board and bracket to wall box.

4. Remove timer circuit board and bracket.

5. Disconnectthe timer cable from timer circuit board.

NOTE: The circuitry on the timer circuit board can be damaged if not properly handled. Do NOTtouch the components on the board. Handle the board by its edges or by the attached bracket.

6. Replace in reverse order.

7. After replacing timer circuit board, check clearance between pushbutton actuator and contact. Push­button should actuate contacts when pressed.

NOTE: It is important the timer circuit board and bracket be installed flush with the finished wall. Failure to do so will result in poor contact between the pushbutton actuator and circuit board switches.

8. If adjustment is necessary, use shims to bring timer circuit board and bracket away from wall box and within reach of pushbutton actuator.

WHIRLPOOL TIMER CONVERSION

Whirlpool Baths equipped with old timers, Model 9680 (timer without digital display) and Model 9681 (timer with LCD), should be replaced if defective with Model 60350 LED Timer. Use Figure 3-3 to identify the timer currently being used on the Whirlpool Bath.

When changing from an old style to a new style timer, it is also necessary to replace the power panel. The following table will help identify the timer and power panel.

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I:] IL

o

-Tub Old New New Power Old Power

Model Timer Timer Panel Panel - -K-783 9680/81 60350 60300 60233 K-792 9680/81 60350 60300 60101 K-802 9680/81 60350 60300 60101 K-1409 9680/81 60350 60300 60233 K-784 9680/81 60350 60300 60229 K-1402 9680/81 60350 60325 60102 K-1410 9680/81 60350 60300 60229 K-1422 60350 60325 K-1482 60350 60325 K-772 60350 60325 -

The timer and power panel are changed using the following procedure:

CAUTION: Before beginning conversion proced ures, turn Whirlpool Bath power OFF.

1. Disconnect 110 VAC from incoming powersupply connection.

2. Remove 90° elbow from motor.

3. Disconnect 110 VAC cable at motor connections.

4. Remove power panel from copper tubing by removing screws and nuts attached to "U" clamps.

NOTE: If new timer cable cannot be installed between power panel and timer location follow the procedures listed below.

5. Cutexisting timer cable as close to existing power panel as possible.

6. Attach new power panel to copper tubing by attaching "U" clamps, screws and nuts.

----, Model 9680 Timer Model 60350 Timer Model 9681 Timer

Rgure 3-3. Timer Control Plates

9

7. Splice existing timer cable to new timer cable on new power panel. Cut to size before splicing.

8. Solder and insulate cables as required.

9. Install replacement 900 elbow (supplied) into motor casing.

10. Install 110 VAC motor leads through elbow and attach to motor connections.

11. Connect 110 VAC leads to incoming powersupply line connection.

NOTE: Disregard level plug connection on side of new power panel.

1. Remove four screws from faceplate of old timer.

COMPONENT IDENTIFICATION LIST

4

2. Carefully remove timer board from masonry box and remove all cable connectors attached to backside of timer board.

3. It new timer cable has not been installed between power panel and timer, cut new cable with con­nector plug, leaving about 12 inches ot cable.

4. Cut oft cable connectors on existing cable near masonry box.

5. Splice 12 inch new cable to existing timer cable.

6. Solder and insulate as required.

7. Connect new cable to timer board.

8. Install timer board and faceplate as specified in timer installation procedures.

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----......... ~-..:.-:::::..- ----

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Wl ~ "-- 5

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Item No. Description Quantil}!' Item No. Description Quantit}!'

1 Masonry Box 4 Machine Screw 4 2 Timer Cable 1 5 Control Plate 1 3 Timer Circuit Board 1 6 Gold-Chrome Insert 2

Figure 3-4. 60350 Electronic Timer

10

SECTION 4- POWER PANEL

THEORY OF OPERATION

The power panel connects the 120 VAC input to the operating circuits of the whirlpool Incoming voltage is connected to the motor and pump through a solid state relay_ A transformer and diode steps down and rectifies the incoming voltage for use by the timer circuitry.

When the relay is closed, 3 to 5 VDC can be read across contacts E and F.

Aschematic of the power panel is shown in Figure 4-1.

SERVICING THE POWER PANEL

The power panel contains two replaceable compo­nents, the transformer and solid state relay. They can be replaced using the following procedure (refer to Figure 4-2):

CAUTION: Turn Whirlpool Bath circuit breaker OFF or otherwise disconnect power from unit before per­forming any maintenance on power panel.

Use a multimeter to check power before replacing any components.

L.evel Sw.

F

J

c

Replacing the Transformer

1. Remove power panel cover by removing four screws.

2. Mark and remove all transformer leads.

3. Remove two screws securing transformer to power panel.

4. Remove transformer.

5. Replace in reverse order. Make sure all connections are secure.

Replacing the Relay

1. Remove power panel cover by removing four screws.

2. Mark and remove all leads attached to relay.

3. Remove relay by removing two screws securing relay to power panel.

4. Replace in reverse order. Be sure heat sink com­pound (supplied) is applied across complete base of relay before installation.

-- -- -- --I ,

~. I ~:;~qD~== L~;' PRIMARY

SEC'~" '''v.,-----',~ III

12.0",

r~1 I

-~

To Molor

Figure 4-1. Power Panel Schematic

11

COMPONENT IDENTIFICATION LIST

Item No. Description Quantity Item No. Description Quantity

1 Electrical Box 1 8 Wiring Harness 2 Electrical Box Cover 1 9 Relay 3 Electrical Box Gasket 1 10 Wiring Harness 1 4 Machine Screw 4 11 Hanger 2 5 Receptacle 1 12 Machine Screw 5 6 Machine Screw 4 13 Bushing 2 7 Transformer 1 14 Machine Screw 2

Figure 4-2. Power Panel

12

SECTION 5- WATER LEVEL CONTROL

THEORY OF OPERATION

The water level control inhibits the operation of the Whirlpool Bath if there is too little water in the tub. Figure 5-1 illustrates how the water level control interfaces with the remaining components of the Whirlpool.

A reed switch in the float chamber assembly, normally closed when the water level is low, grounds one of the pins of the microprocessor causing a flashing "L" to appear on the digital display.

When sufficient water is in the tub, the float in the float chamber assembly rises causing the reed switch to open. Because the microprocessor pin is no longer grounded, the motor and pump can be engaged when the "L" stops flashing and a time appears on the digital display. A 10-second delay may be experienced after the reed switch opens and the "L" stops flashing.

A breather valve located above the float chamber assembly allows ai r to escape as the chamber fills with water. The float chamber assembly is connected to the tub by a copper tube. Water from the tub enters the tube through an inlet located in one of the jet assem­blies.

NOTE: Location of the three-hole retainer is important to the operation of the water level control. Refer to Section 9 Trim Kits for proper location.

SERVICING THE WATER LEVEL CONTROL

The water level control consists of a breather valve, float chamber assembly and connecting tubing. Under normal operating conditions these parts should only require occasional cleaning. However, should they become defective they can be replaced using the following procedures.

Breather Valve

The breather valve can be removed and cleaned using the following procedure (refer to Figure 5-2):

CAUTION: When replacing breather valve, ensure that the flexible plastic tubing is not kinked or bent. This could obstruct air flow.

1. Use screwdriver to gently pry breather valve from securing bracket located on underside of tub.

Air Vent Hole

Securing

Breather -Valve

/'

Bracket

//

Jet Assembly (Inside Tub)

\

Waler Level Inlet

Copper Tubing

/'

___ Flexible Plastic Tubing

Float Chamber

A-I[--</ .... mblY

~ .. /~~>// rr~/ III ( Power

'==~ WlJ/ ~'--<ll V Figure 5-1. Water Level Control

13

2. Disconnect flexible plastic tubing from float cham­ber assembly.

3. Remove breather valve and flexible plastic tubing.

4. Clean flexible plastic tubing and breather valve port. Be sure to remove any dirt or other foreign objects that may obstruct flow of air.

5. Replace in reverse order.

Float Chamber Assembly

Thefloat chamber assembly can be removed from the water level control by using the following procedure (refer to Figure 5-2):

1. Disconnect copper tubing from bottom of float chamber assembly.

2. Disconnect level control plug from power panel.

3. Remove two screws securing float chamber as­sembly to harness bracket.

4. Remove flexible plastic tubing connecting breather valve to float chamber assembly.

5. Remove float chamber assembly.

6. Replace in reverse order.

The float chamber assembly can be disassembled for cleaning or service by using the following procedure (refer to Figure 5-2):

1. Remove level switch sub assembly.

2. Remove C-clip from level switch sub assembly.

3. Remove float and gasket from level switch sub assembly.

4. Clean float chamber, level switch sub assembly and float. Clean inlet and outlet ports of float chamber. Ensure there are no obstructions to water flow.

5. Replace in reverse order.

6. When reassembling float chamber assembly, en­sure grooved portion ottloat is located at bottom of level switch sub assembly.

14

COMPONENT IDENTIFICATION LIST

Item No.

1 2 3 4 5 6 7 8

1_~

2-'~ U

'-$!' ,

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'---....0 6 -------t:)

,

2J

'''et /' @~ . ~

Description

Breather Valve Flexible Tube Spring Clip Level Switch Sub Assembly Gasket Float Float Chamber Sleeve

Figure 5-2. Water Level Control

Quantity

1 1 1 1 1 1 1 1

SECTION 6- MOTOR AND PUMP

THEORY OF OPERATION

The motor and pump work as a unit; the motor provides the drive power for the pump impeller.

The whirling action of the impeller creates a vacuum, pulling water into the inlet port. The incoming water is forced through the impeller and out through the water harness.

Adjustable jets, located on the sides of the tub, provide outlets for the circulating water and serve to divert the flow of the water for more effective whirlpool action.

Figure 6-1 illustrates how air is asperated into the water stream as the water passes through the adjust­able jets. The amount of air mixed with the water is controlled by the adjustable air control located on top of the tub.

SERVICING THE MOTOR AND PUMP

The motor and pump should be removed from the Whirlpool Bath for all service and maintenance activ­ities, Removal and replacement can be accomplished using the following procedure:

CAUTION: Turn Whirlpool Bath circuit breaker OFF or otherwise disconnect power from unit before per­forming maintenance on motor and pump.

1. Disconnect pump from suction and harness tubes.

2. Disconnect ground strap.

CAUTION: Be careful not to strip threads in tub.

3. Remove bolts securing motor and pump to tub.

Air/Water Mixture

Air

Figure 6-1. Water/Air Mixture

4. Remove motor and pump.

S. Disconnect motor power cord from power panel.

6. Replace in reverse order.

Once the motor and pump has been removed, deter­mine which model had been installed. Follow service procedures for that model only.

ITT MARLOW 60041, 60097 AND 60388-M MOTOR AND PUMP

The ITT Marlow 60041,60097 and 60388-M motor and pump can be disassembled for service using the following procedure (refer to Figure 6-2):

1. Removescrews securing casing to motor. Remove casing.

2. Lift off diffuser and gasket.

3. Hold motor shaft by inserting screwdriver into slot provided in motor casing; or remove motor end cover and hold shaft with an open end wrench.

4. Rotate impeller counterclockwise and remove.

5. Slide rotating member of seal assembly off impeller shaft.

6. Remove diffuser O-ring and seal plate gasket.

7. Remove screws and lockwashers securing seal plate and bracket to motor housing. Remove seal plate and bracket.

8. Remove stationary members of seal assembly by pushing out from behind seal plate and bracket. Use only fingers, not a screwdriver or other sharp object which may damage components.

9. Check impeller, diffuser, diffuser O-ring, gasket and seal assembly. If any item is damaged or worn, replace it. Impeller, casing and diffuser are a matched set; replace at the same time.

10. Clean impeller and ali seal assembly cavity sur­faces thoroughly before reassembling.

11. Secure seal plate to motor housing.

12 Install stationary members of seal assembly into the seal plate. Lubricate gasket with clean water only.

CAUTION: When installing seal assembly mem­bers, do not use a screwdriver or other sharp object which may damage ceramic ring.

13. Seat stationary members firmly, using finger pres­sure only.

15

14. Slide rotating member of seal assembly onto impeller shaft. Lubricate with clean water only.

15. Ensure grooved portions of rotating member are located over raised portions of impeller shaft

16. Hand tighten impeller onto motor shaft.

17. Place diffuser over Impeller with word "TOP" at top. Stop lug will be in 6 o'clock position. Ensure the O-ring is securely in place.

18. Lubricate with water. Then place gasket in groove on seal plate and bracket Ensure gasket is sealed properly.

19. Replace pump casing and secure in place.

ITT MARLOW 60186, 60187, 60478, 60479, 60660-M,60661-M,604S7,60S01,60662-M ANO 60663-M MOTOR ANO PUMP

The ITT Marlow60186, 60187, 60478, 60479, 60660-M, 60661-M, 60457, 60501, 60662-M and 60663-M motor

COMPONENT IDENTIFICATION LIST ITT Marlow 60041, 60097 and 60388-M Motor and Pump

5 •

3

Item No. Description Quantity

1 Casing 1 2 Gasket 1 3 Diffuser 1 4 Impeller 1 5 Seal Assembly 1 6 Gasket 1 7 Screw 4

and pump can be disassembled for service using the following procedure (refer to Figure 6-3):

9

1. Remove screws secunng pump casing to face plate. Remove casing.

2. Hold motor shaft by inserting a screwdriver into slot provided in motor casing; or remove motor end cover and hold shaft with an open end wrench

3. Rotate impeller counterclockwise and remove.

4. Slide rotating member of seal assembly off im-peller shaft.

5. Remove face plate O-ring.

6. Remove face plate from motor housing.

7. Remove stationary members of seal assembly by pushing out from behind plate. Use only fingers, not a screwdriver or other sharp object which may damage components.

8. Check impeller, O-ring and seal assembly. If any item is damaged or worn, replace it. Impeller and

12

Item No. Description Quantity

8 Lockwasher 4 9 Seal Plate 1

10 Screw 8 11 Slinger 1 12 Motor 1 13 O-Ring 1

Figure 6-2. Motor and Pump

16

COMPONENT IDENTIFICATION LIST ITT Marlow 60186, 60187, 60478, 60479, 60660-M, 60661-M, 60457, 60501, 60662-M and 60663-M Molorand Pump

8

7 ----~ , 1 4

3

--~

Item No. Description Quantity Item No. Description Quantity

1 Casing 1 5 Seal Assembly 1 2 Screw 6 6 Face Plate 1 3 O-Ring 1 7 Slinger 1 4 Impeller 1 8 Motor 1

Figure 6-3. Motor and Pump

casing are a matched pair; replace both at the same time.

g, Clean impeller hub and all seal assembly cavity surfaces.

10. Install face plate on motor housing.

11. Install stationary members of seal assembly into face plate. Lubricate O-ring with clean water only.

CAUTION: When installing seal assembly mem­bers, do not use a screwdriver or other sharp object which may damage ceramic ring.

12. Seal stationary members firmly using finger pres­sure only.

13. Slide rotating member of seal assembly onto impeller shaft. Lubricate with clean water only.

14. Ensure grooved portions of rotating member are located over raised portions of impeller shaft.

15. Hand tighten impeller onto motor shaft.

16. Install O-ring on face plate.

17. Replace pump casing and secure in place.

HAYWARD 60660-H AND 60661-H MOTOR AND PUMP

The Hayward 60660-H and 60661-H motor and pump can be disassembled for service using the following procedure (refer to Figure 6-4):

1. Remove screws securing pump casing to seal plate. Remove casing.

2. Hold motor shaft by inserting a screwdriver into slot provided in motor casing; or remove motor end cap and hold shaft with an open end wrench.

3. Rotate impeller counterclockwise and remove.

4. Slide rotating member of seal assembly off im­peller shaft.

5. Remove motor end cap.

6. Remove screws securing seal plate to motor housing.

7. Remove stationary members of seal assembly by pushing out from behind seal plate. Use only fingers, not a screwdriver or other sharp object which may damage components.

17

8. Remove slinger from motor shaft.

9. Check impeller, D-ring, shaft sleeve and seal assembly. If any item is damaged orworn, replace it. Impeller and casing are a matched pair: replace both at the same time.

10. Clean impeller hub and all seal cavity surfaces.

11. Install slinger on motorshaft. Ensurethatflange of slinger is facing threaded end of shaft.

12. Install D-ring on ceramic seal member. Ensure it is properly seated.

13. Press ceramic ring into clear plastic retainer.

14. Attach seal plate to motor housing.

15. Install D-ring on cut ridge of clear plastic retainer.

COMPONENT IDENTIFICATION LIST Hayward 60660-H and 60661-H Motor and Pump

, e?~1

Item No. Description Quantity

1 Screw 6 2 Casing 1 3 D-Ring 1 4 Impeller 1 5 Seal Assembly 1 6 Seal Plate 1 7 Slinger

CAUTION: When installing seal assembly mem­bers, do not use a screwdriver or other sharp object which may damage components.

16. Press assembled stationary members of seal as­sembly into seal plate. Lubricate with clean water only. Seal assembly should be pressed in with D-ring toward motor and exposed face of the ceramic ring toward impeller.

17. Slide rotating member of seal assembly onto impeller shaft. Lubricate with clean water only.

18. Hand tighten impeller onto motor shaft.

19. Install D-ring on seal plate.

20. Replace pump casing and secure in place.

Item No. Description Quantity

8 Motor 1 9 Screw 4

10 End Cap 1 11 Insulating BUShing 2 12 Insulating Bushing 2 13 Nut 6

Figure 6-4. Motor and Pump

18

•

SECTION 7- TRIM KITS

SERVICING THE TRIM KITS

Trim kit components are designed for long life. How­ever, if one needs to be replaced, use the following procedures (refer 10 Figure 7-1):

Air Control Assembly

The air control assembly is serviced using the follow­ing procedure (refer to Figure 7-1):

1. Raise trim cap and remove setscrew located 'In a'rr control body_

2. Unscrew control knob.

3. Replace parts as needed and clean all surfaces before reassembly.

4. Install setscrew into air control body, leaving several threads exposed outside body.

5. Place trim cap over air control body.

6. Screw knob into body about eight turns.

7. Lift trim cap and tighten setscrew until it makes contact with knob shaft.

8. Back setscrew off 1/4 turn.

9. Check knob for proper installation by turning counterclockwise until it stops. Knob shOuld not unscrew from air control body.

10. If knob unscrews from body, remove knob and trim cap. Repeat steps 6 through 10. increasing number of turns in step 7 by 1/2 until knob no longer unscrews from air control body.

11. Apply small amount of RTV sealant to underside of trim cap.

12. Line up dimple in trim cap with setscrew in air control body.

13. Carefully push trim cap onto air control body.

14. Fill any gaps between trim cap and control body with RTV. Remove any excess RTV from around air control assembly.

Adjustable Jets

The adjustable jets are serviced using the following procedure (refer to Figure 7-1):

1. Remove two screws securing assembly to jet housing.

2. Pull on center of ball and remove assembly from housing. Assembly may be tightly sealed. If nec­essary, use small Phillips screwdriver in screw hole to remove assembly.

3. Disassemble assembly into ball, O-ring, retainer and plastic insert bearing.

4. Remove trim ring.

5. Replace parts as required and clean all surfaces before reassembly.

.

NOTE: Some retainer assemblies have three 1/4" holes drilled into them. These holes are required for proper operation of water level control. If retainer with three holes is being replaced, it must be replaced with a similar retainer. Three hole retainers are located on Whirlpool Baths as follows:

-Whirlpool Location of Jet Housing

Model With Three Holes·

GuardIan K-783-S, Left Rear Steeping Bath K-792-S, Caribbean K-802-S, Barbados K-1409

Guardian K-784-S, Right Rear Barbados K-1410

The Super Bath K-1422 1st Jet Housing Clockwise From the Drain

Infinity'~ 00 K-1482 Left of Suction Hood Location IS referenced from a normal seating position In the tub.

6. Remove dirt, grease, moisture and RTV from jet housing flange.

7. Apply RTV sealant to underside lip of trim ring.

S. CarefUlly snap trim ring into flange on tub. Ensure that dimples in trim ring align with notches in jet housing.

9. Apply light film of lubricant to two a-rings and plastic insert bearing.

10. Install a-rings on retainer. One is installed inside, the other in groove on outside of retainer.

11. Assemble ball and plastiC insert bearing into retainer.

12. Insert ball and retainer into jet housing, being careful not to drop plastic bearing into housing.

NOTE: The retainer assembly with three 1/4" holes must be installed so hole for water level control is toward bottom of tub and aligns with hole in jet housing. Water level control hole should be free of all RTV, dirt and lubricant and be completely unobstructed to ensure proper water level control operation.

19

13. Align screw holes and secure retainer to jet housing.

14. Tighten screws until ball moves freely with slight side to side pressure.

Suction Inlet

The water suction inlet is serviced using the following procedure (refer to Figure 7-1):

COMPONENT IDENTIFICATION LIST

Item No. Description Quantity

1 Control Knob 2 2 O-Ring 2 3 Trim Cap 2 4 Setscrew 2 5 O-Ring 4 6 Screw 2 7 Retainer 1

1 Remove screw securing suction hood and screen to inlet housing.

2. Remove hood and hair screen.

3. Replace any parts as necessary and clean all surfaces before reassembly.

4. Fit hair screen into groove on back of hood.

5. Attach screen and hood squarely to inlet housing Ensure riveted portion of screen is located toward bottom of tub.

6. Secure hood and screen into place.

.--::::.-.

Item No. Description Quantity

8 O-Ring 9 Directional Ball 1

10 Insert Beari ng 1 11 Trim Ring 1 12 Screw 1 13 Suction Hood 1 14 Hair Screen 1

Figure 7-1. Trim Kits

20

•

SECTION 8- INFINITY BATH FAUCET FITTINGS

COMPONENT IDENTIFICATION LIST

Item No.

1 2 3 4 5 6 7 8 9

10 11

'_~ ) ~:;..,-:-

'-0 '--1 4_~

-,--

'-@ I

(4~ , __ L_

------------

Description Quantity Item No.

Cap 2 12 O-Ring 2 13 Screw 2 14 Handle 2 15 Lock Ring 2 16 Bonnet 2 17 O-Ring 2 18 O-Ring 2 19 Washer 2 20 Stem 2 21 Plunger with Seat Washer 2 22 and Screw

Figure 8-1. Faucet Fittings

Description

Seat Washer Screw Sleeve Renewable Seat Lift Knob Diverter Replacement lift Knob Lift Rod Retainer Cap Retainer Escutcheon

Quantity

2 2 2 2 1 1 1 1 1 1 1

21

COMPONENT IDENTIFICATION LIST

r -- _ ' ____ 3

') /' 2 I,.,c I IIi. r ) 6 I 1, ~ ,- l'

, J

1

1-16-...... ----

Item No. Description Quantity Item No. Description Quantity

1 Screw 2 16 Ell & Tube SA 1 2 Hood 1 17 Nut 1 3 Nut 1 18 Gasket 1 4 Lift Rod 19 Tee 1 5 Lift Rod 20 Gasket 1 6 Safety Rod 1 21 Nut 1 7 Nut 1 22 Drain Ell & Tube 1 8 Washer 1 23 Gasket 1 9 Link 1 24 Strainer 1

10 Spring 1 25 Lift Toggle 1 11 Nut 1 26 Nut 1 12 Gasket 1 27 Stopper 1 13 Clamp 1 28 O-Ring 1 14 Tube 1 29 Tailpiece 1 15 Clamp 1

Figure 8-2. Drain FIttings

22

SECTION 9- OLD STYLE TIMERS AND POWER PANELS

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24

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26

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27

Umlted One-Year Warranty

Kohler plumbing fiKtures and fittings are warranted free of manufacturing dofects.

Kohler Co. will at ItsaJectlon repair, replace or make appropriate adjustment where Kohler Co. inspection discloses any such defects occurring in normal usage Mthin one year after installation. Kohler Co. Is nol _ponti .. tor l",laIlatIon eottl..

To obtain warranty service. contact KohJer Co. either through your Dealer or Plumbing COntractor or by writing Kohler Co., Attn: Consumer Affairs Department. Kohler, Wisconsin 53044 U.S.A.

Implied ~rrant'" Including ~ 01 merchantability aree.pressly limlted IndulIIUon 10 lheduratlonolltlilwarranty. Kohlltr Co. disclaim. any responslbUIly for consequential dlllTl8gllS. Some stales do not allow limitations on how long an implied warranty lasts. or the ellClusion or limitation of inc identa l or consequential damages, so th is limitation and eKclusion may not apply to you. This warranty gives you specific legal rights. You may also have other rights which vary from state to stale.

This is our exclusive written warranty.

KOHLER