PARTS CATALOG - Guillen`s Enterprises, Inc.
Contents
1. Figure 9 2 9880 Non LCD Timer Component Diagram 24 von 40 2 hil ERERAUELIC SELECT JUMPER DOOD One TOPAT L502 4 1 d OTOOTO KAKAL V vec st V V 4 zu pf D urs qb 5 5 53 V Ra HUM esM r V D 3yg vee vee m e Q0 seg M m PA E Figure 9 3 9681 LCD Timer Schematic Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 25 RESISTORS OK Git cx Re le SEEAF TERM IG ORAN TAT OAS AS 4 4724 020 MAE FAS ALTERNATE TAB PPLER uhar T K AW ON 72 Ave 0 004 AW v 420 yw 2058 a 1 b 9 CAPACITOR gt vertus 4 IAFD 4 douf 25v HFG MO p mE I m Guillen s Enterprises inc Original Kohler Parts n pec oe uillens com 5 a 222 7855 cl CDI EFT ZENER BidOe leper a 20v 5 e DARN Figure 9 4 9681 LCD Timer Component Diagram VOTES Ow 2 020001 5 s 216929 veered TACTA C 2976 15 CONG an Gis acareQ d rQwv uk Caeli i AC LINE TO MOTOR Figure 9 5 9680 9681 Timers Power Pane2. 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 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 impelier O ring shaft sleeve and seal 10 11 12 13 14 15 assembly If any item is damaged or worn repiace it Impeller and casing are a matched pair replace both at the same time Clean impeller hub and all sea 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 property seated Press ceramic ring into clear plastic retainer Attach seal plate to motor housing Instali O ring on cut ridge of clear plastic retainer COMPONENT IDENTIFICATION LIST Hayward 60660 H and 60661 H Motor and Pump 18 Item No Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Description Quantity Screw 6 Casing O Ring Impeller Seal Assembly Seal Plate Slinger 16 18 18 20 Item No CAUTION When installing seal assembly mem bers do not use a screwdriver or other sharp object which may damage components Press assembled stationary me
3. Kohler Genuine Parts Catalog www qguillens com Kohler Parts KOHLER 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 KOHLER e ls 4 V WHIRLPOOL 2 SERVICE MANUAL gt P pr Guillen s Enterprises inc s Fas Original Kohler Parts a Pap sl wh guillens com 800 222 7855 2 T 7 t 9 eli E SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 This manual covers service and maintenance procedures for the following Kohler Whirlpool models e Super Bath Whirlpool K 1422 Infinity Bath Whirlpool K 1482 K 1484 Caribbean Whirlpool K 802 e Steeping
4. L to appear on the digital display When sufficient water is in the tub the float in the float chamber assembiy 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 airto 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 assem blies Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Jet Assembly Inside Tub Water Level 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 flexibl
5. Lift Rod Safety Rod Nut Washer Link Spring Nut Gasket Clamp Tube Clamp Item No Quantity 2 ab b i ee Figure 8 2 Drain Fittings Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Description amp Tube S A Nut Gasket Tee Gasket Nut Drain Ell amp Tube Gasket Strainer Lift Toggle Nut Stopper O Ring Taitpiece Quantity ast et SECTION 9 OLD STYLE TIMERS AND POWER PANELS Lone peo SABLE FREGUEUCY l VCC SELEGT JUMPER E vcc 559 veo MSO 48 lt g EAG KX GAANDE KDA ic 3 UOCE X GG X eX R 1 vee AL D E beadada H CCo 32 8 VOIOOO tor R 4 vec Figure 9 1 9680 Non LCD Timer Schematic Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 23 INLO VAT i xad BACK vig Le CHR OUT BOARD TERM AS ORE TAT OAL n 2 I OOK AW 10 Pe TOR y 2 ais 8 5 5 Li 9 8 H MPG AD 2 CAPACITORS 2 VALUE auf 25 B Guillen s Enterprises inc Original Kohler Parts meg 0 ae guillens com 800 222 7855 2 lt 2 vera user nv ci D 845 PEEB 5 H g 6 2 5
6. Quantity Item No Figure 2 2 Whirlpool Bath Description Adjustable Air Control Adjustable Jets Water Suction Inlet Timer Cable Quantity 2 1 1 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 THEORY OF OPERATION Power for the timer Figure 3 1 provided by the power panel is betwee VDC and 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 Black Yellow or To White Power Red Panel Green Figure 3 1 Timer Board SECTION 3 TIMER 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
7. 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 TROUBLESHOOTING Continued SYMPTOMS PROBABLE CAUSES RECOMMENDED ACTION 11 Pump runs and trips GFCI 1 Bad bearing in pump Replace pump breaker 2 Loose electrical connections Secure all contacts Guillen s Enterprises inc 3 GFCI trips at less than 5 Replace breaker Original Kohler Parts milliamperes guillens com 4 Ground fault in system Disconnect wires from relay Check 800 222 7855 resistance between case and terminals If below 100 kilohms replace relay Whirlpool starts itself 1 Notona separate circuit Wire electrical supply on separate Circuit 2 Power outage lightning voltage Replace 60347 printed circuit spike transient noise board 3 Contaminants sawdust metal Clean or replace 60347 printed shavings on 60347 timer board circuit board 4 Faulty relay Replace relay Whirlpool timer flashes L 1 Water in tub not 2 above jets Add water 7 when START STOP pushed 2 Three hole retainer in jet See trim kit installation assembly in wrong location instructions 3 Airlock in breather Clean breather orifice and observe water to fil up into clear tube equal to water level in tub 4 Obstruction in line from three Remove cover of float control and hole
8. retainer to float control run wire to orifice hole in jet assembly 5 Failure on 60347 printed circuit Disconnect float control plug from board assembly or in timer power pack If timer still flashes cable L replace 60347 timer board EE END Also check control cable for nails No display timer dead 1 Face plate not making contact Masonry box not flush with with foils for set time and finished wall see installation START STOP instructions for 60350 timer 2 No output on secondary side of Replace transformer transformer 6 14VDC 3 Timer cable connection loose or Secure connection or replace damaged at timer prongs 60318 timer cable Timer LED missing legs 1 Timer circuitry defective Replace timer 60347 printed circuit _ Whirlpool flashes L with 1 Three hole retainer in jet See trim kit installation tub full assembly in wrong location instructions 2 Water level sensor float Invert float reversed Whirlpool does not flash L 1 Level float plug disconnection Insure connection witn tub empty Pump runs but no whirlpool 1 Brass orifices missing behind jet Install orifices action assembly 2 Suction blocked Clear suction COMPONENT IDENTIFICATION LIST Item No Description 1 Timer 2 Power Panel 3 Water Level Control 4 Motor and Pump Depends on model Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855
9. 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 compo nents on the various models Guillen s Enterprises inc Original Kohler Parts at guillens com 800 222 7855 1754 2 Guardian The Super Bath Steeping Bath 1 Adjustable Jet 4 Water Suction Inlet 2 Adjustable Air Control 5 Safety Grip Handle 3 Motor and Pump Figure 1 2 Component Locations Barbados SECTION 2 GENERAL SYSTEM DESCRIPTION THEORY OF OPERATION Each electronically actuated Kohler Whirlpool Bath consists of five basic components 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 Whirl pool 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 WATER FLOW Basic water flow for the Kohler Whirlpool Bath is depicted in Figure 2 1 Once filled with
10. 479 60660 M 60661 M 60457 60501 60662 M AND 60663 M MOTOR AND PUMP The ITT Marlow 60186 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 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Description Quantity Casing Gasket Diffuser Impeller Seal Assembly Gasket Screw and pump can be disassembled for service using the following procedure refer to Figure 6 3 1 Remove screws securing pump casing to face plate Remove casing 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 Rotate impeller counterclockwise and remove Slide rotating member of seal assembly off im peller shaft 5 Remove face plate O ring 6 Remove face plate from motor housing Remove stationary members of seal assembly by pushing out from behind plate Use only fingers nota screwdriver or other sharp object which may damage components Check impeller O ring and seal assembly If any item is damaged or worn replace it Impeller and Description Quantity Lockwasher Seal Plate Screw Slinger Motor O Ring 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 Motor and P
11. Bath Whirlpool K 792 e Guardian Whirlpool K 783 K 784 e Barbados Whirlpool K 1409 K 1410 e Pristine Whirlpool K 772 TABLE OF CONTENTS GENERAL INFORMATION SECTION 6 MOTOR AND PUMP 1 THEORY OF OPERATION 15 WARNINGS AND PRECAUTIONS 1 SERVICING THE MOTOR AND PUMP 15 SERIAL NUMBER LOCATION 1 ITT MARLOW 60041 60097 AND 60388 M SERVICE AND MAINTENANCE 2 MOTOR AND PUMP 15 COMPONENT LOCATIONS 3 COMPONENT IDENTIFICATION LIST 16 GENERAL SYSTEM DESCRIPTION ITT MARLOW 60186 60187 60478 60479 THEORY OF OPERATION 4 POSSUM 60661 M 60457 60301 60662 WATER FLOW uo OUUU 4 AND 60663 M MOTOR AND PUMP 16 TROUBLESHOOTING 5 COMPONENT IDENTIFICATION LIST 17 PH d en HAYWARD 60660 H AND 60661 H COMPONENT IDENTIFICATION LIST 7 MOTOR SNDIBUMB C cicer uh i7 TIMER COMPONENT IDENTIFICATION LIST 18 TE ORY or OET 8 SECTION TRIM KITS PU PATRE RVICING THE TRIM KITS 19 WHIRLPOOL TIMER CONVERSION 9 e Control Aemilio 19 COMPONENT IDENTIFICATION LIST 10 Adjustable Jets 19 POWER PANEL Suction Inlet 20 THEORY OF OPERATION 11 COMPONENT IDENTIFICATION LIST 20 SERVICING THE POWER PANEL 11 COMPONENT IDENTIFICATION LIST 12 SECTION 8 INFINITY BATH FAUCET FITT
12. INGS COMPONENT IDENTIFICATION LIST 21 WATER LEVEL CONTROL THEORY 13 SECTION 9 23 SERVICING THE WATER LEYEL IIIS ttttttt ttt tt ttn CONTROL 554 erecto ee 13 Breather 13 Float Chamber 14 COMPONENT IDENTIFICATION LIST 14 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 INTRODUCTION The purpose of this manual is threefold to provide familiarization with Kohier Whirlpool Bath operation to provide detaiied maintenance and functional check out instructions and to provide comprehensive re placement 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 Allelectrical work shall be performed by a qualified electrician or ASR 4 Pump motor may oper
13. ate 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 prior to repair or service 6 Local electrical codes may require use of a Ground Fault Circuit Interrupter GFCI on circuits sup plying power to the Whirlpool Bath Kohler Com pany recommends the use of a 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 Kohier Company reserves the right to implement product changes without prior notice 10 Kohler Company will not assume responsibility for product performance or safety where replace SECTION 1 GENERAL INFORMATION 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 s
14. 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 fol lowing 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 SCHEMATIC DIAGRAM Figure 3 2 Timer Schematic 3 Remove screws securing timer circuit board and bracket to wall box 4 Remove timer circuit board and bracket 5 Disconnect the timer cable from timer circuit board NOTE The circuitry on the timer circuit board can be damaged if not properly handled Do NOT touch 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 Push button should actuate contacts when pressed NOTE It is important the timer circuit board and bracket be installed flush with the finish
15. ce 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 Suction Inlet Ensure riveted portion of screen is located toward The water suction inlet is serviced using the following bottom of tub procedure refer to Figure 7 1 6 Secure hood and screen into place Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 COMPONENT IDENTIFICATION LIST Item No Description Quantity Item No Description Quantity Control Knob 8 O Ring O Ring 9 Directional Ball Trim Cap 10 Insert Bearing Setscrew 11 Trim Ring O Ring 12 Screw Screw 13 Suction Hood Retainer 14 Hair Screen Figure 7 1 Trim Kits 20 SECTION 8 INFINITY BATH FAUCET FITTINGS COMPONENT IDENTIFICATION LIST Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Item No Description Quantity Item No Description Quantity Cap 2 Seat Washer O Ring 2 Screw Screw 2 Sleeve Handle 2 Renewable Seat Lock Ring 2 Lift Knob Bonnet 2 Diverter Replacement O Ring 2 Lift Knob O Ring 2 Lift Rod Washer 2 Retainer Cap Stem 2 Retainer Plunger with Seat Washer 2 Escutcheon and Screw 4 sot 1 Figure 8 1 Faucet Fittings 21 COMPONENT IDENTIFICATION LIST 22 Item No 1 OM Description Screw Hood Nut Lift Rod
16. e 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 Alr Vent b Hole Securing Bracket we Flexible Plastic Tubing Float Chamber Figure 5 1 Water Level Control 13 2 Disconnect flexible plastic tubing from float cham ber 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 The float chamber assembly can be removed from the water level contro by using the following procedure refer to Figure 5 2 1 Disconnect copper tubing from bottom of float chamber assembly 2 Disconnect level contro plug from power panel 3 Remove two screws securing float chamber as sembly 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 assembiy and float Clean inl
17. ed 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 panei The following table will help identify the timer and power panel Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 New New Power Old Power Timer 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 procedures turn Whirlpool Bath power OFF 1 Disconnect 110 VAC from incoming power supply connection 2 Remove 90 elbow from motor 3 Disconnect 110 VAC cable at motor connection
18. erial number is a 10 character code provided on each Whirlpool Bath to establish a uniform method of permanently marking each unit The seria 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 Code Pre Jan 1 1983 Code Post Jan 1 1983 Manufacturing Facility Brownwood Richmond Spartanburg Toledo Wisconsin 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 Month January July February August September October March April May November June December Serial Number Location EN NI G aii om Gi Cy TE ca a Figure 1 1 Serial Number Location In Plant Identif
19. et 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 en sure grooved portion of float is located at bottom of level switch sub assembly Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 14 COMPONENT IDENTIFICATION LIST Item No 4 0 nn Description Breather Valve Flexible Tube Spring Clip Level Switch Sub Assembly Gasket Float Float Chamber Sleeve Figure 5 2 Water Level Control Quantity b 2 Guillen s Enterprises inc Original Kohler Parts guillens com 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 divertthe 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 adjust able jets The amount of air mixed with the water is controlled by the adjustable air contro located on top of the tub SERVICING THE MOTOR AND PUMP The motor and pump should be removed from
20. ication 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 X 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 83 0006 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 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 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 CAUTION When servicing the power panel motor and pump or any other portion of the system where high voltages may be present ensure
21. ing Bath K 792 S Caribbean K 802 S Barbados K 1409 Guardian K 784 S Barbados K 1410 The Super Bath K 1422 Right Rear 1st Jet Housing Clockwise From the Drain Infinity 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 8 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 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 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 jethousing 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 1 Remove screw securing suction hood and screen to housing inlet housing 14 Tighten screws until ball moves freely with slight 2 Remove hood and hair screen side to side pressure 3 Repla
22. l Wiring Diagram 26 TEM Euccasvee STAN AS BER Wares PO COAL STE or Oa OE BE VRS IT OF Innes BA E 1492 B Qna 2 cues 0 3 ARF PS 2a E C GREKU IPVA TROL 4 ENC OSQRE e Al 9 Dom VOLTAGE 2225 ME EIE RED 2 voc WHITE Rev Cow BE WHO ASOT PRIMARY VOLTAGE NOVATA v GA Wibe 0 6700 4 VOLTAGE LOW VOLTHGE BO GA Y AFP Figure 9 6 9680 9681 Timers Power Panel Schematic Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Figure 9 7 9680 9681 Timers Power Panel Components Diagrams 27 Publication Number 105582 0483 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 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 me
23. mbers of seal as sembly into seal 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 impeiler Slide rotating member of seal assembly onto impeller shaft Lubricate with clean water only Hand tighten impeller onto motor shaft Install O ring on seal plate Replace pump casing and secure in place Description Quantity Motor 1 Screw End Cap Insulating Bushing Insulating Bushing Nut Figure 6 4 Motor and Pump 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 refer to Figure 7 1 Air Control Assembly The air control assembly is serviced using the follow ing procedure refer to Figure 7 1 1 Raise trim cap and remove setscrew located in air 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 severai 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 f
24. old timer timer installation procedures COMPONENT IDENTIFICATION LIST 10 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Item No Description Quantity Item No Description Quantity 1 Masonry Box 4 Machine Screw 4 2 Timer Cable 5 Control Plate 1 3 Timer Circuit Board 6 Gold Chrome Insert 2 Figure 3 4 60350 Electronic Timer 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 compo nents the transformer and solid state relay They can be replaced using the following procedure refer to Figure 4 2 CAUTION Turn Whirlpoo Bath circuit breaker OFF or otherwise disconnect power from unit before per forming any maintenance on power panel Use a multimeter to check power before replacing any components Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Replacing the Transformer 1 Remove power pane cover by removing four SCrews 2 Mark and remove all transformer leads 3 Remove two screws
25. rchantability 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 notapply 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 KOHLER KOHLER CO KOHLER WISCONSIN 53044
26. rom 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 tn 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 t 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 nec essary use small Phillips screwdriver in screw hole to remove assembly SECTION 7 TRIM KITS 3 Disassemble assembly into ball O ring retainer and plastic insert bearing 4 Remove trim ring 5 Replace parts as required and ciean 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 Location of Jet Housing With Three Holes Left Rear Whirlpool Model Guardian K 783 5 Steep
27. s 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 LU clamps screws and nuts Modei 60350 Timer Model 9681 Timer Figure 3 3 Timer Control Plates 8 Solder and insulate cables as required 9 Install replacement 90 elbow supplied into 10 11 Splice existing timer cable to new timer cable on 2 Carefully remove timer board from masonry box new power panel Cut to size before splicing and remove all cable connectors attached to backside of timer board 3 If new timer cable has not been installed between motor casing power panel and timer cut new cable with con nector plug leaving about 12 inches of cable Install 110 VAC motor leads through elbow and attach to metoreonneetiohs 4 Cut off cable connectors on existing cable near masonry box Connect 110 VAC leads to incoming power supply line connection 5 Splice 12 inch new cable to existing timer cable 6 Solder and insulate as required NOTE Disregard level plug connection on side of new power panel 7 Connect new cable to timer board 8 Install timer board and faceplate as specified in Remove four screws from faceplate of
28. 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 pane 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 com pound supplied is applied across complete base of relay before installation PRIMARY Figure 4 1 Power Panel Schematic 11 COMPONENT IDENTIFICATION LIST Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Description No Description Quantity Item No 1 Electrical Box 1 8 2 Electrical Box Cover 1 9 3 Electrical Box Gasket 1 10 4 Machine Screw 4 11 5 Receptacle 1 12 6 Machine Screw 4 13 7 Transformer 1 14 12 Figure 4 2 Power Panel Wiring Harness Relay Wiring Harness Hanger Machine Screw Bushing Machine Screw Quantity 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
29. the Whirlpool Bath for ail service and maintenance activ ities Removal and replacement can be accomplished using the following procedure CAUTION Turn Whirlpool Bath circuit breaker OFF or otherwise disconnect power from unit before per forming maintenance on motor and pump 1 Disconnect pump from suction and harness tubes 2 Disconnect ground strap CAUTION Be carefu not to strip threads in tub 3 Remove bolts securing motor and pump to tub Air Water Mixture Figure 6 1 Water Air Mixture SECTION 6 MOTOR AND PUMP 4 Remove motor and pump 5 Disconnect motor power cord from power panel 6 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 ITT MARLOW 60041 60097 AND 60388 M MOTOR AND PUMP The ITT Marlow 60041 60097 and 60388 M motor and pump be disassembled for service using the following procedure refer to Figure 6 2 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 seal plate gasket 7 Remove screws and lockwashers securing seal plate and bracket
30. 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 all seal assembly cavity sur faces 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 mem bers do not use a screwdriver or other sharp object which may damage ceramic ring 13 Seat stationary members firmly using finger pres sure 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 60
31. ump 9 10 11 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Item No Description Quantity Casing Screw O Ring Impeller Item No Description Quantity Seal Assembly Face Plate Slinger Motor 5 6 7 8 Figure 6 3 Motor and Pump casing are a matched pair replace both at the same lime Clean impeller hub and all seal assembly cavity surfaces Install face 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 bers do not use a screwdriver or other sharp object which may damage ceramic ring Seal 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 ring on face piate 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
32. water the Whirlpool Bath 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 Guillen s Enterprises inc Original Kohler Parts guillens com 800 222 7855 Adjustable Jet Air Control Adjustable Je ES Adjustable Control Adjustable Figure 2 1 Water Flow Guillen s Enterprises inc Original Kohler Parts 800 222 7855 guillens com 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 ___ RECOMMENDED ACTION 1 Pump not pumping 1 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 Motor does not turn 21 No power to motor Check that ali power switches are on Be sure fuse or circuit breaker is properly set Check that time is set properly Low
33. water flow 1 Suction air leak 7 Tighten all clamp fittings on or clogged _ Orifice jet assembly missing Install orifice 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 bearings on motor Have electrician replace motor Motor overload suction side of pump 2 Discharge jets partially closed Clean clogged jets Motor is impro perly connected Check wiring diagram on motor Low voltage due to undersized Check with volt meter Increase wire or low voltage size of supply wire Report low supply voltage to power company Voltage at motor must be within 10 of motor nameplate voltage during operation NOTE Electrical work must be 5 done by a qualified electrician or an authorized Kohler service representative amp Water leaking along pump 7 1 Worn pump seal pump and replace shaft 22 m seal 7 Timer display lights with set 1 Defective timer Replace circuit board time but pump does start 2 Faulty timer cable Replace cable when START STOP activated _ u 3 Faulty relay Replace relay 8 Pump always on while power 1 Defective relay low or no Replace relay applied to system voltage at relay input i t 9 Pump running slow and erratic 1 Low voltage to pump from high Check voltage at pump Replace with growling
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