PARTS CATALOG - Guillen`s Enterprises, Inc.
Contents
1. Kohler Genuine Parts Catalog Guillen www quillens com Kohler Parts KOHLER 7 GENUINE PARTS Your place for parts PARTS CATALOG ORDER HELP 1 Locate the desire replacement part number Open guillens com website enter the part number at the Search field at the top Select the correct option provided and place the order online or 2 Call 800 222 7855 Open 24 hours or Call 305 226 7855 Open 8 30am to 5 00pm M F or 3 ContactUs via E mail Guillen s Enterprises Inc Since 1973 Kohler 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 2 0 Ea runoa JT FT ee ee o T eee ek ee ee TOOL ee Er 1 Een E by u 1 1 gt Bc ES byi aa E a a Sr EE AL pup Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 a VON em nuls ear a ESL ES ei 0m 1 9 73 Je 4 7 2 a oo Pn PFET F SENN 0 i i Emu vns With Air Actuator Aspirat2. Parts Catalog This service manual applies to Whirlpool Baths with the series code SA only For Whirlpool Baths with series codes other than SA or no series code refer to the following e Kohler Whirlpool Service Manual With Electronic Timer Publication Number 105582 e Kohler Whirlpool Service Manual With Air Actu ated Controls Publication Number 105583 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 H H Spartanburg B S Toledo A A Wisconsin D 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 April D October J May E November K June F December L In Plant Identification The fifth through eighth characters numeric in the string of numbers are used for in plant identification 800 222 7855 SECTION 2 GENERAL SYSTEM DESCRIPTION THEORY OF OPERATION of the air switch relay and timer assembly refer Each air actuated Kohler Whirlpool Bath typically to Figure 2 1 cons
3. Removal and replacement can be accomplished using the following procedure WARNING Turn GFCI OFF 1 Disconnect pump from suction and harness tubes CAUTION Be careful not to strip threads on studs 2 Remove bolts or nuts and washers securing motor and pump to tub 3 Remove motor and pump 4 Disconnect motor power cord leads from air switch power module at the motor 5 Replace in reverse order Once the motor and pump has been removed deter mine which model had been installed Follow service procedures for that model only KOHLER MODELS 60660 M AND 60661 M MOTOR AND PUMP These models are 1 2 horsepower assemblies iden tical in all aspects except for casing alignment with motor body For right or left outlet installation The Kohler 60660 M or 60661 M motor and pump can be disassembled for service using the following pro cedure refer to Figure 5 3 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 12 bers do not use a screwdriver or other sharp object which may damage ceramic ring Seat stationary members firmly using finger pres sure only Slide rotating member of seal assembly onto impeller shaft Lubricate with clean water only Ensure grooved portions of rotating member are located over raised portions of impeller shaft Hand tighten impeller onto motor shaft Install O
4. the pump motor and timer PC board circuitry After approximately 20 minutes of operation the timer circuitry deactivates power to the pump motor stop ping the whirlpool action If the air actuator aspirator control is pressed while the whirlpool pump is on the air pulse again momentarily closes the air switch and relay in the power panel interrupting power to the pump motor and stopping the whirlpool action The timer PC board then automatically resets at approximately 20 minutes SERVICING THE POWER PANEL Servicing the power panel is limited to replacement of defective components To service the power panel proceed as follows CAUTION Turn GFCI OFF before servicing the power panel 1 Remove screws securing electrical box cover to electrical box Remove electrical box cover Remove and replace gasket if damaged Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 10 Quantity 2 AQ Description Bolt Washer Screw Enclosure Hanger Cable Assembly Cable Assembly Air Switch Tube COMPONENT IDENTIFICATION LIST Quantity Item No 4 10 1 11 1 12 1 13 2 14 1 15 1 16 4 17 1 Figure 4 1 Power Panel Assembly Description Screw Cover Gasket Air Switch Assembly Holder PC Board Timer Relay screw Mounting Bracket Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 item No OOYY OO
5. Figure 5 6 1 Remove screws 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 face plate gasket 7 Remove screws and lockwashers securing face plate and bracket to motor housing Remove face plate and bracket 8 Remove stationary members of seal assembly by pushing out from behind face plate and bracket CAUTION Use only fingers not a screwdriver or other sharp object which may damage com ponents 9 Check impeller diffuser diffuser O ring gasket Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Y Quantity 4 1 8 1 1 1 Description Washer Face Plate Bracket Screw Slinger Motor O Ring COMPONENT IDENTIFICATION LIST Kohler Model 60388 M Motor and Pump Quantity Item No 8 9 10 11 12 13 D Figure 5 6 Motor and Pump Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Description Casing Gasket Diffuser Impeller Pump Seals Gasket screw Item No J O U Lo N SECTION 6 TRIM KITS 3 Replace any parts as necessary and clean all surfaces
6. 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 Adjustable Jets Plastic The adjustable jets are serviced using the following procedure refer to Figure 6 2 1 Using a small screwdriver loosen the ball lock ring 2 Remove ball and lock ring from jet housing 3 Using 2 9 16 inch socket wrench remove the orifice from the jet housing 4 Replace parts as required and clean all surfaces before reassembly 5 Assemble orifice into jet housing 6 Assemble ball and ball lock ring into jet housing Tighten with small screwdriver NOTE See Section 7 for expanded service of Plastic Jets and Suction Suction Inlet Plastic The water suction inlet is serviced using the following procedure refer to Figure 6 2 1 Remove screw securing suction hood to inlet housing 2 Remove hood from inlet housing by unscrewing hood counterclockwise 3 Replace any parts as necessary and clean all surfaces before reassembly 4 Secure hood into place 5 Install screw securing suction head to inlet housing WARNING The whirlpool must not be operated without the suction hood installed NOTE See Section 7 for expanded service of Plastic Jets and Suction SERVICING THE ASPIRATOR ASSEMBLY Refer to SECTION 3 SERVICING THE ACTU ATOR ASPIRATOR A
7. in January e Manufactured post January 1 1983 60 W Wisconsin manufacturing facility 8 Manufactured in the 80 s 3 Manufactured in 1983 B Manufactured in February SERVICE AND MAINTENANCE Kohler Whirlpool Baths require a minimum of mainte nance for trouble free operation Removal and re placement 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 performed by an Authorized Service Representative ASR WARNING When servicing the power panel assembly 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 furnished with air switch controls series SA Al though component configuration may differ from model to model operation and service are relatively the same Guillen s Enterprises inc Original Kohler Parts guillens com The series code indicates the following e SA Whirlpool Timing System with air actuator aspirator and air switch controls e Refer to Plate Number SA in the SP3A Service
8. ring on seal plate Replace pump casing and secure in place 12 13 14 15 16 17 Item No Description Quantity 5 Pump Seals 1 6 Seal Plate 1 7 Slinger 1 8 Motor 1 CAUTION Use only fingers not a screwdriver or other sharp object which may damage com ponents Check impeller O ring and seal assembly If any item is damaged or worn replace it Impeller and casing are a matched pair replace both at the same time Clean impeller hub and all seal assembly cavity surfaces Install seal plate on motor housing Install stationary members of seal assembly into face plate Lubricate O ring with clean water only CAUTION When installing seal assembly mem 10 11 COMPONENT IDENTIFICATION LIST Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Item No Description Quantity Casing Screw O Ring Impeller AONI O Figure 5 3 Motor and Pump 13 Kohler Models 60660 M and 60661 M Motor and Pump d P4 Check impeller O ring shaft sleeve and seal assembly If any item is damaged or worn replace it Impeller and casing are a matched pair replace both at the same time Clean impeller hub and all seal cavity surfaces Install slinger on motor shaft Ensure that flange of slinger is facing threaded end of shaft Install O ring on ceramic seal member Ensure it is properly seated Press ceramic ring into clear plast
9. z ai det E i a Br gt To M 5 ii w 2 P Xin ka A A i k ri 37 un r X i Tt ad P i m ja quz iE 1 53 7 aue zh 8 B um an TAA se m EL i carat yr i A E mo 1 Yu l ly i ee Lo EFL y Ig d wae E73 we LM TT T ag j UY apre TF a ber E 3 Lag b aX iy pet m HE 4 F t 1 r 1 Fi 5 ee 7 E ai S pe 1 RN E MA a PUE ELE k ee Ss al m j 1 i d A 2 a on J d Cna A CIN Tae dn pe Ld T uet b EL A x Dy O M f FT e 1 o 1 idm r AC 4 wd Ti a 7 5 La P y pb nn j 5 T A LT A an TU e a 8 is T c ji t2 am M angi iy Ta p a a j 1 P m ray va Bare en rl UTE al fr ru at m e tec m Y Vr e KY qz o E T I Lo B 8 d 1 T x Br ra a ee SEE ax p ii ma a Guillen s Enterprises inc Original Kohler Parts guillens com This manual cover
10. ERVICING THE ASPIBATOR ASSEMBLY 19 COMPONENT IDENTIFICATION LIST 9 cp SECTION 4 POWER PANEL ASSEMBLY AE e as 20 THEORY OF OPERATION 10 COMPONENT IDENTIFICATION LIST SERVICING THE POWER PANEL PLASTIC eua ER PR EA 21 ASSEMBLY cse Er Ea kas 10 COMPONENT IDENTIFICATION LIST 11 SECTION 7 PLASTIC JET AND SUCTION SERVICE SERVICING PLASTIC JET ASSEMBLY AND SECTION 5 MOTOR AND PUMP SUCTION ASSEMBLY 22 THEORY OF OPERATION 12 COMPONENT IDENTIFICATION LIST 22 SERVICING THE MOTOR AND PUMP 12 COMPONENT IDENTIFICATION LIST 23 KOHLER MODELS 60660 M AND 60661 M COMPONENT IDENTIFICATION LIST 24 MOTOR AND PUMP 12 SERVICE NOTE ia ore meer Rea s reg 24 COMPONENT IDENTIFICATION LIST 13 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 SECTION 1 GENERAL INFORMATION 10 Kohler Company will not assume responsibility for product performance or safety where replace 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 AND SERIES CODE LOCATION The serial number is an 8 character code assigned to each Whirlpool Bath to provide a uniform method of permanently identifying each unit The series code isa two 2 character a
11. NEL ASSEMBLY Mark and disconnect leads to air switch assembly Remove air switch from electrical box by de pressing retainer tabs Disconnect plastic tubing from air switch Loosen screws securing relay mounting bracket to electrical box Remove relay and PC board bracket from electrical box Mark and disconnect leads from relay Replace components as necessary Connect leads to replacement relay CAUTION Leads must be installed on terminals as outlined on Wiring Diagram Figure 2 3 Failure to install leads on correct terminals will result in erratic operation of the Whirlpool Bath Install replacement relay and PC board mounting bracket in electrical box Tighten screws securely Connectleads to air switch and install air switch in electrical box Connect plastic tubing to air switch Install gasket on electrical box cover Install cover and gasket on electrical box Install screws securing cover and gasket to elec trical box Tighten screws securely Turn GFCI ON and fill Whirlpool Bath Test operation of power panel 10 THEORY OF OPERATION The power panel consists of the electrical box cover gasket air switch assembly PC board and relay refer to Figure 4 1 When the whirlpool is off and the air actuator aspirator control is pressed the air pulse momentarily closes the air switch and relay in the power panel The air switch and relay in turn activates the power supply to
12. SSEMBLY Omit references to the air bellows All other service procedures are the same 19 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 SERVICING THE TRIM KITS Trim kit components are designed for long life How ever if one needs to be replaced use the following procedures Adjustable Jets Brass The adjustable jets are serviced using the following procedure refer to Figure 6 1 1 Remove two screws securing retainer to jet housing 2 Pull on center of ball and remove assembly from housing Assembly may be tightly sealed If nec essary 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 only if it is damaged It may be sealed with RTV sealant 5 Replace parts as required and clean all surfaces before reassembly 6 If trim ring is removed and replaced remove dirt grease moisture and RTV from jet housing flange 7 Apply RTV sealant to underside lip of trim ring 8 Carefully snaptrim 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 O rings and plastic insert bearing 10 Install O 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 h
13. al Plate 1 3 O Ring 1 7 Slinger 1 4 Impeller 1 8 Motor 1 Figure 5 5 Motor and Pump D 16 and all pump seals If any item is damaged or worn replace it Impeller casing and diffuser are a matched set replace at the same time Clean impeller and all seal assembly cavity sur faces thoroughly before reassembling Secure face plate to motor housing 12 Install stationary members of seal assembly into the face plate Lubricate gasket with clean water only CAUTION When installing seal assembly mem bers do not use a screwdriver or other sharp object which may damage ceramic ring Seat stationary members firmly using finger pres sure only Slide rotating member of seal assembly onto impeller shaft Lubricate with clean water only Ensure grooved portions of rotating member are located over raised portions of impeller shaft Hand tighten impeller onto motor shaft 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 Lubricate with water Then place gasket in groove on face plate and bracket Ensure gasket is sealed properly Replace pump casing and secure in place 17 10 11 13 14 15 16 17 18 19 KOHLER MODEL 60388 M MOTOR AND PUMP This model is a 1 horsepower assembly The Kohler Model 60388 M motor and pump can be disassembled for service using the following pro cedure refer to
14. bb VON C Guillen s Enterprises inc Original Kohler Parts guillens com SECTION 5 MOTOR AND PUMP Air Water Mixture Figure 5 1 Water Air Mixture Brass Whirlpool System Water Air Mixture Figure 5 2 Water Air Mixture Plastic Whirlpool System 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 seal plate O ring 6 Remove seal plate from motor housing 7 Remove stationary members of seal assembly by pushing out from behind plate 800 222 7855 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 Figures 5 1 and 5 2 illustrate how air is aspirated into the water stream as the water passes through the adjustable jets The amount of air mixed with the water is controlled by the two adjustable air aspirators 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 activ ities
15. djustable Jet Adjustable Jet Air a Suction Adjustable Inlet Jet Figure 2 2 Water and Air Flow TROUBLESHOOTING FLOW CHART NOTE This flow chart has been designed as a7 step checklist procedure to be performed by a Kohler START Authorized Service Representative ASR 1 Fili Whirlpool Bath above jets 2 Turn supply GFC breaker on Electrical connections tight and installed correctly Water leaks YES moisture GFCI damaged defective wiring YES GFCI installed L a GFCI stays on properly YES 3 Press air actuator aspirator YES Air tubing Relay starts l YES Replace air Power on loose kinked motor when Motor a Whirlpool action starts Switch running or filled with switched assembly water manually YES Electrical l YES YESI suction YES connections YES Pump impeller f YES Replace Jets open clear tight and loose on Impeller installed motor shaft correcily YES YES e YES YES Orifices connections b Whirlpool water flow through all jets sufficient for installed in All jets open tight and Suction Blockage in Blockage in good whirlpool action jets installed clear pump casing piping correctly YES Air injection maximum when air actuator Motor voltage Reduce or OK refer to increase Replace pump motor face supply and motor plate Voltage OK 4 Turn air ac
16. ic retainer Attach face plate to motor housing Install O ring on cut ridge of clear plastic retainer CAUTION When installing seal assembly mem bers do not use a screwdriver or other sharp object which may damage components Press assembled stationary members of seal as sembly into face plate Lubricate with clean water only Seal assembly should be pressed in with O ring toward motor and exposed face of the ceramic ring toward impeller Slide rotating member of seal assembly onto impeller shaft Lubricate with clean water only Hand tighten impeller onto motor shaft Install O ring on face plate Replace pump casing and secure in place 9 10 11 12 13 14 15 16 17 18 19 20 KOHLER MODELS 60660 H AND 60661 H MOTOR AND PUMP These models are 1 2 horsepower assemblies iden tical in all aspects except for casing alignment with motor body For right or left outlet installation The Kohler 60660 H or 60661 H motor and pump can be disassembled for service using the following pro cedure refer to Figure 5 4 1 Remove screws securing 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 cap 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 motor end cap 6 Remove screws securi
17. installation costs To obtain warranty service contact Kohler Co either through your Dealer or Plumbing Contractor or by writing Kohler Co Attn Consumer Affairs Department Kohler Wisconsin 53044 U S A Implied warranties including that of merchantability are expressly limited in duration to the duration of this warranty Kohler Co disclaims any responsibility for consequential damages Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so this limitation and exclusion may not apply to you This warranty gives you specific legal rights You may also have other rights which vary from state to state This is our exclusive written warranty J KOHLER Publication Number 100194 0884 KOHLER CO KOHLER WISCONSIN 53044
18. ists of four basic components e Power panel assembly which includes air switch e Tub which acts as a reservoir for the water and relay and timer assembly to drive the motor and provides a location for whirlpool action pump e Motor and pump which provide the power to e Air control actuator aspirator whi urns th 20 ME move the water and create the whirlpool action Whirlpool Bath ON and OFF through activation COMPONENT IDENTIFICATION LIST 2 M T COT See UT 6 1 E 7 i MA L I 1 1 9 2 v Item No Description Item No Description 1 Motor and Pump 4 Adjustable Jets 2 Aspirator Actuator 5 Water Suction Inlet 3 Power Panel Assembly 6 Adjustable Air Aspirator Valve Figure 2 1 Whirlpool Components Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 WATER AND AIR FLOW pulled into the pump and forced back out to the tub Basic water flow for the Kohler Whirlpool Bath is 0 87 depicted in Figure 2 2 Once filled with water the Air is mixed with the water stream at the jets and Whirlpool Bath becomes a self contained system adjusted using the air aspirator controls Water is drawn from the tub through the water suction This cycle continues as long as the motor and pump inlet typically located near the bottom of the tub are operating Guillen s Enterprises inc Motor and Pump Original Kohler Parts guillens com 800 222 7855 Aspirator A
19. ket by turning counter clockwise Make sure there is complete engage ment of the wrench pins in the wall flange sockets to prevent damage to flange or bath walls 5 Cutall water and air supply tubes to damaged jet housing CAUTION DO NOT CUT ANY CLOSER THAN 3 FROM THE JET Item No Description Quantity 3 Wall Flange 1 4 Gasket 1 5 Suction Housing 1 2 SERVICING PLASTIC JET ASSEMBLY AND SUCTION ASSEMBLY Kits are available through your Kohler Service Parts Supplier which include the components illustrated in Figures 7 1 and 7 2 Also included are adjacent fittings and short pieces of flexible PVC tubing To service the jet and suction assemblies using the repair kits follow these procedures 1 Analyze the damaged jet adjacent fittings and tube diameters Choose the parts in the kit needed for the repair job 2 Provide suitable protection for acrylic surfaces of the bath COMPONENT IDENTIFICATION LIST Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Bath Shell N Item No Description Quantity 1 Screw 1 2 suction Hood Includes Item 1 1 Figure 7 1 Suction Assembly 22 COMPONENT IDENTIFICATION LIST Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 4 3 5 Bath Shell dy item No Description Quantity Item No Description Quantity 1 Wall Flange Includes 3 Orifice 1 Item 5 1 4 Housing 1 2 Gasket 1 5 Ball and Retainer Figu
20. l connections tight and installed correctly Shuts off with FYES Actuator Aspirator YES YES Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Motor temperature YES YES Suction Jets open normal below clear 160 F YES Electrical connections tight and Replace relay PC YES YES GFCI breaker reset board assembly installed correctly The Whirlpool Bath is now operating properly The following are troubleshooting steps dealing with inconsistent or erratic operation Remove A Actuator 6 Whirlpool starts or stops when air actuator aspirator is YES Aspirator is NO Moisture in rotated plastic tubing spirator blocked Inspect for damage and replace Power panel vES Separate 110 Powerotage L NO wired 7 Whirlpool starts with no user activity 120 VAC voltage spike correctly circuit See diagram on page 7 8 Whirlpool continues to run after approximately 20 YES Refer to min actuator inoperative 117 VAC Line Pump Motor 1 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 PC Board WHT GRY BLK GRY BLK Air Switch Assembly x BLK Relay BLK WHT BLK Figure 2 3 Wiring Diagram SECTION 3 AIR ACTUATOR ASPIRATOR ASSEMBLY from body unless it is seriously damaged The housing cannot be repaired u
21. lpha code identifying a specific feature of the Whirlpool model and is located on the same label as the serial number Both codes are located on a label attached to the Whirlpool Bath pipe harness return line directly above the air switch power panel It is visible after installation with the access panel removed refer to Figure 1 1 All warranty reports and invoices must include the serial number and series code The serial number indicates the following e Manufacturing facility The decade in which it was manufactured The year of manufacture The month of manufacture In plant identification Serial Number and Series Code Label Location Figure 1 1 Serial Number and Series Code Location INTRODUCTION The purpose of this manual is twofold to provide familiarization with Kohler Whirlpool Bath operation and to provide detailed maintenance and functional check out instructions 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 Whenservicing the power panel motor and pump or any portion of the system where high voltages may be encountered ensure power t
22. ng face plate to motor housing 7 Remove stationary members of seal assembly by pushing out from behind face plate CAUTION Use only fingers not a screwdriver or other sharp object which may damage com ponents 8 Remove slinger from motor shaft Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 14 COMPONENT IDENTIFICATION LIST Kohler Models 60660 H and 60661 H Motor and Pump 9 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 o Item No Description Quantity Item No Description Quantity 1 Screw 6 8 Motor 1 2 Casing 1 9 Screw 4 3 O Ring 1 10 End Cap 1 4 Impeller 1 11 Insulating Bushing 2 5 Pump Seals 1 12 Insulating Bushing 2 6 Face Plate 1 13 Nut 6 7 Slinger 1 Figure 5 4 Motor and Pump KOHLER MODELS 60662 M AND 60663 M MOTOR AND PUMP Guillen s Enterprises inc These models are 3 4 horsepower assemblies iden Original Kohler Parts tical in all aspects except for casing alignment with guillens com motor body For right or left outlet installation 800 222 7855 The Kohler Model 60662 M or 60663 M motor and pump can be disassembled for service using the same procedures outlined for disassembly and service as the 60660 M and 60661 M See page 13 of this manual COMPONENT IDENTIFICATION LIST Kohler Models 60662 M and 60663 M Motor and Pump Item No Description Quantity Item No Description Quantity 1 Casing 1 5 Pump Seals 1 2 Screw 6 6 Se
23. nless a special tool is obtained The tool is available from Kohler Con sumer Affairs 5 Remove housing from body using a special tool and turning counterclockwise 6 Remove gasket 7 Replace parts as necessary To reassemble 1 Install housing into body from inside of bath and tighten clockwise NOTE Use teflon tape on hous ing threads The use of RTV silicone sealant should be avoided 2 Attach plastic tubing to bellows Install air bellows and gasket in housing 3 Install air control actuator assembly in housing The stationary lugs toward the bottom of the air control actuator assembly must align with the matched grooves molded into the housing The retainer tabs must align with the slots at the top of the housing Press and snap into place 4 Apply small amount of RTV sealant under tapered trim cap Press tapered trim cap onto housing 5 Align drive lugs on air control actuator assembly with matching holes in underside of dual control aircap Press dual control aircap onto air control actuator assembly 6 Fill Whirlpool Bath Turn GFC ON and test for proper operation THEORY OF OPERATION When the air control actuator is pressed an air bellows located in the housing is compressed Atthis pointthe air bellows delivers a pulse of air to the power panel and the power panel starts the pump and motor SERVICING THE ACTUATOR ASPIRATOR ASSEMBLY Servicing the air actuator aspirator assembly is limited
24. o the Whirl pool Bath is OFF 3 Allelectrical work shall be performed by a qualified electrician or ASR 4 Pump motor may operate at high temperatures avoid coming in contact with motor shell while pump motor is operating or shortly after shut down 5 After servicing the Whirlpool Bath always re install all safety devices as originally found priorto repair or service 6 Localelectrical codes may require use of a Ground Fault Circuit Interrupter GFCI on circuits sup plying power to the Whirlpool Bath Kohler Com pany requires 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 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 2 Examples e Manufactured pre January 1 1983 D78A0006 D Wisconsin manufacturing facility 7 Manufactured in the 70 s 8 Manufactured in 1978 A Manufactured
25. or Control For SA Series Whirlpool Baths LE zT M ij 1 aod it J a o i N ol Li d Ti 3 p LI aom t t PL F r 4 7 A i a nt aT 4 1 7 a AN us 9 d 3 e a f E Lr T i i k E Li wo eS Ww 4 QE d A a7 L 9 A i m i B A ades Tw m i 1 amp 5 i E LN i Pin i 7 1 m E a T X ui a W mik nil Lr i Lu k 4 bh d a e d H a t res i 73 Le 5 aci Oe a E ng a wd ES 3 i ey pa 8 w Ta ri JI t a 2 a 8 x L E E FIT F Q a bos i 5 i aaf 3 LIC um m HN a A Es br Es mu Ll ig m t AL ra a a M om us ual eu diio um i ta Rome 5 tO ag iT E a 5 1 s i P m LF i YF s aia 3 i Dd cem Ru NT P AF d ry Ur a aF u a E a A ix 4 at Er k x iW Fa 5 F i E Tia nell d dl Ps de N IMS CILE AC dn M F i 1 Ten Foro aee uL E el a
26. ousing being careful not to drop plastic bearing into housing 13 Align screw holes and secure retainer to jet housing 14 fighten screws until ball moves freely with slight side to side pressure Suction Inlet Brass The water suction inlet is serviced using the following procedure refer to Figure 6 1 1 Remove screw securing suction hood and screen to inlet housing 2 Remove hood and hair screen Description Retainer O Ring Directional Ball Insert Bearing Trim Ring Screw Suction Hood Screen COMPONENT IDENTIFICATION LIST BRASS Item No 7 8 9 10 11 12 13 14 Figure 6 1 Trim Kits Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Item No Description 1 Dual Control Aircap Includes Item 2 2 spring Ring 3 Tapered Trim Cap 4 Aircap Includes Item 2 5 O Ring 6 screw 20 21 COMPONENT IDENTIFICATION LIST PLASTIC 7 6 1 Description Quantity Item No Description Control Knob Adjustable Ball O Ring Orifice Trim Cap Screw Setscrew Suction Hood Ball Retaining Ring Figure 6 2 Trim Kits Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 SECTION 7 PLASTIC JET AND SUCTION SERVICE 3 Remove all attachments to the wall fitting flange including ball and retainer assembly or suction hood cover 4 Remove the wall fitting flange with a jet spanner wrench and ratchet soc
27. re 7 2 Jet Assembly Cut lengths of flexible tubing allowing enough length for complete seating in the jet and coupling sockets Slip fit the flexible tubes and temporarily install the housing to the wall flange without gluing or sealing to ensure that your measurements are correct Keep the housing aligned with the hole and cement the tubes to the housing and couplings Reinstall the wall flange to the housing with the gasket behind the bath wall beveled edge to the wall Draw a bead of silicone around the flange being sure to avoid the threads Thread the flange into the housing Before tightening completely 23 9 Salvage and clean all removed parts including beveled gasket wall flange jet orifice and orifice insert for possible reuse Inspect thoroughly for damage before reusing Clean all old RTV silicone sealant from hole Using the PVC primer and cement follow the manufacturer s instructions install suitable tube couplings to the cut ends of the air or water supply tubes Clean and cement suitable reducing bushings plugs or adapters to the new jet or suction housing Place the new housing over the hole and determine the proper length of flexible tubing required to bridge the distance between the jet and water and air supply tubes COMPONENT IDENTIFICATION LIST Item No Description Quantity Knob Trim Cap Collar C Clip Actuator Housing Fastener Figure 7 3 Actuator Assembl
28. s service and maintenance procedures for the following Kohler Whirlpool models e SUPERBATH WHIRLPOOL K 1422 SA 800 222 7859 e Infinity oo Bath WHIRLPOOL K 1482 SA K 1484 SA e CARIBBEAN BATH WHIRLPOOL K 802 SA e STEEPING BATH WHIRLPOOL K 792 SA e GUARDIAN BATH WHIRLPOOL K 783 SA K 784 SA e BARBADOS BATH WHIRLPOOL K 1409 SA K 1410 SA e PRISTINE BATH WHIRLPOOL K 772 SA e Greek BATH WHIRLPOOL K 1492 SA e Hourglass X Bath WHIRLPOOL K 1512 SA TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION KOHLER MODELS 60660 H AND 60661 H INTRODUCTION MOTOR AND PUMP 14 WARNINGS AND PRECAUTIONS COMPONENT IDENTIFICATION LIST 15 SERIAL NUMBER AND SERIES CODE KOHLER MODELS 60662 M AND 60663 M LOCATION 1 MOTOR AND PUMP 16 SERVICE AND MAINTENANCE 2 COMPONENT IDENTIFICATION LIST 16 SECTION 2 GENERAL SYSTEM DESCRIPTION ROB EEE NODE See MMO TOR THEORY OF OPERATION 000 3 cm bi COMPONENT IDENTIFICATION LIST 3 9 ENN 0 WATER AND AIR FLOW 4 SECTIONG TRIM KITS TROUBLESHOOTING FLOW CHART 5 SERVICING THE TRIM KITS 19 WIRING DIAGRAM sess 7 Adjustable Jets Brass 19 SECTION 3 AIR ACTUATOR ASPIRATOR ASSEMBLY UU E s THEORY OF OPERATION 8 0 05150 6 ASNC eagrain 12 SERVICING THE AIR ACTUATOR Suction Inlet Plastic 19 ASPIRATOR ASSEMBLY 8 S
29. to replacement of defective components refer to Figure 3 1 WARNING Turn GFCI OFF before servicing The air control actuator assembly may be serviced using the following procedure 1 Gently pry dual control aircap from air control actuator assembly 2 Gently pry tapered trim cap from housing CAUTION Tapered trim cap may be sealed with RTV sealant Use care when removing tapered trim cap as not to damage finish 3 While gently pulling outward on air control actuator assembly depress both retainer tabs on sides of control and remove assembly from housing 4 Remove air bellows from housing Remove plastic tubing from air bellows CAUTION Do not allow plastic tube to fall inside tub enclosure You may not have access to recover the tube NOTE The dual control aircap tapered trim cap air control actuator air bellows and gasket may be replaced at this point Do NOT remove housing Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 COMPONENT IDENTIFICATION LIST C Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 a be Item No Description Quantity Item No Description Quantity 1 Dual Control Aircap 1 5 Air Bellows 1 2 opring Ring Part of Item 1 1 6 Gasket 1 3 Tapered Trim Cap 1 7 Housing 1 4 Air Control Actuator 8 Gasket 1 Assembly 1 9 Body 1 Part of Trim Kit Figure 3 1 Actuator Aspirator Assembly SECTION 4 POWER PA
30. tuator aspirator fully counterclockwise then fully clockwise Actuator Orifices Aspirator installed in blocked jets NO Replace Actuator Aspirator Any air aspirator fully counterclockwise stops when fully injected clockwise blocked YES 7 Air injection b eum shuts off ctuator Aspirator Press air actuator aspirator wait 30 seconds press again Electrica Air tubing connections YES st 1t L a Whirlpool action stops when button is pressed ops won R ef then starts again when button is pressed again loose kinked restart or broken installed correctly Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 CONTINUED ON NEXT PAGE Replace relay PC board assembly NO Pump impeller jammed or blocked Piping jammed or Motor vents blocked blocked Replace pump motor Tubing kinked around piping Replace Air Switch Assembly Functions Replace Air properly Switch Assembly Water in or otherwise Relay resets actuator crimped or after each tubing wrapped command CONTINUED YES NO f Stops before NO O v Whirlpool continues to run for 20 minutes when 20 minutes Doesn t stop Refer to restarted then shuts off automatically 2 min Step 8 YES NO Electrica
31. y apply a bead of silicone sealant between the rear bath wall and the beveled side of the gasket Complete tightening until the gasket begins to compress CAUTION DO NOT OVERTIGHTEN If the gasket pops out loosen the wall flange and repeat the process 13 Wipe away excess silicone from the inside of the bath wall and apply silicone around the housing at the rear of the unit Clean the inside of the unit before silicone cures 14 Make sure that you have installed the correct orifice insert into the new housing 15 Replace the wall fitting attachments For example ball and retainer or suction cover 16 Allow 3 hours for a complete cure of silicone and PVC cement before testing Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 SERVICE NOTE K 1512 SA Hourglass Whirlpools and K 1492 SA Greek Whirlpools are still equipped with air actuator assemblies shown in Figure 7 3 Refer to KOHLER WHIRLPOOL SERVICE MANUAL No 105583 for actuator service instructions 24 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Limited One Year Warranty Kohler plumbing fixtures and fittings are warranted free of manufacturing defects Kohler Co will at its election repair replace or make appropriate adjustment where Kohler Co inspection discloses any such defects occurring in normal usage within one year after installation Kohler Co is not responsible for
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