Download PARTS CATALOG - Guillen`s Enterprises, Inc.
Transcript
Kohler Genuine Parts Catalog www.guillens.com Kohler 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 - Contact Us 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 KOHLER WHIRLPOOL With Electronic TImer ~~Wll~rn; WiU~If{I1l1J~IL Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 , , , ,. , , ."" ' , , , , ,• .. • , .• • " , 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: • • • • • • • Super Bath™ Whirlpool Infinity BathTM Whirlpool CaribbeanT" Whirlpool Steeping Bath™ Whirlpool GuardianTM Whirlpool Barbados™ Whirlpool Pristme'M Whirlpool K-1422 K-1482, K-1484 K-802 K-792 K-783, K-784 K-1409, K-1410 K-772 TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION INTRODUCTION ... WARNINGS AND PRECAUTIONS. SERIAL NUMBER LOCATION SERVICE AND MAINTENANCE. COMPONENT LOCATIONS ..... SECTION 2 GENERAL SYSTEM DESCRIPTION ......... THEORY OF OPERATION WATER FLOW ..................... TROUBLESHOOTING .... ......... COMPONENT IDENTIFICATION LIST. SECTION 3 TIMER THEORY OF OPERATION ..... SERVICING THE TIMER WHIRLPOOL TIMER CONVERSION. COMPONENT IDENTIFICATION LIST .. SECTION 4 POWER PANEL THEORY OF OPERATION. SERVICING THE POWER PANEL COMPONENT IDENTIFICATION LIST. SECTION 5 WATER LEVEL CONTROL THEORY OF OPERATION SERVICING THE WATER LEVEL CONTROL ............. Breather Valve ....................... Float Chamber ......... COMPONENT IDENTIFICATION LIST. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 2 3 4 4 5 7 8 8 9 10 11 11 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 ........... Air Control Assembly ........ Adjustable Jets.. Suction Inlet ... . .... COMPONENT IDENTifiCATION LIST ... 19 19 19 20 20 12 SECTION 8 INFINITY BATH FAUCET FITTINGS COMPONENT IDENTIFICATION LIST ... 21 13 SECTION 9 OLD STYLE TIMERS AND POWER PANEL ... . ............... 23 13 13 14 14 Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 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 Facility Code Pre Jan. 1, 1983 Code Post Jan. 1, 1983 Brownwood Richmond Spartanburg Toledo Wisconsin C T R R B A 0 A W S 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 January February March April May June Code A B C 0 E F Month July August September October November December Code G H I J K L Serial Number ,, __ :.7" -\l}) -,-TI LlJ 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. Follows the eighth 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. • Manufactured pre January 1, 1983. D78A0006/X. Only commonly used tools are required to service Kohler Whirlpool Baths, however, a multimeter is required to test the electrical components of the system. Whirlpool Designate Code character of the string as "IX." Examples: - 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. 8. 3. B. Wisconsin manufacturing facility. Manufactured in the 80's. Manufactured in 1983. 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 2 SERVICE AND MAINTENANCE 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 , Caribbean , 4 4':" 5 ,-itl . . . d, 4 5 2 Infinity 00 Bath Pristine 1_2 2 5 2 -- 1 ~~l " . I 3 3 Guardian --t-=_ The Super Bath 1. Adjustable Jet 2. Adjustable Air Control 3. Molor and Pump Steeping 8ath II tt' , -~--- 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 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 Whirlpool Bath is in operation. • Power panel which provides electricity to drive the motor and pump. Air Control • 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. Adjustable 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 4 o Legend D Water D Air Figure 2-1. Water Flow I Guillen's Enterprises, inc Original Kohler Parts guillens.com TROUBLESHOOTING 800-222-7855 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 Pump not pumping. PROBABLE CAUSES Low water level in tub (below jets). 2. Suction air leak. = ~CO""MENDED ACTION Fill tub to proper level 2. Motor does not turn. 1. No power to motor. Tighten all clamps and fittings on suction side of pump. Check that all power switches are on. Be sure fuse or circuit breaker is properly set. 3. Low water flow. 1 . Suction air leak. Check that time is set properly. Tighten all clamp fittings on suction side of pump. r- 4. Noisy operation. 5 Motor overload. 2. Discharge jets partially closed or clogged. Clean clogged jets. 3. Orifice jet assembly missing. 1. Air leak in suction line. Install orifice. Repair leak. Check suction pipe. Tighten clamps. 2 Restricted suction line due to blockage. Remove blockage. 3 Bad beanngs on motor. 1. Motor is improperly connected. Have electrician replace motor. Check wir"tng diagram on motor. NOTE: Electrical work must be 2. Low voltage due to undersized done by a qualified electrician wire or low voltage. or an authorized Kohler service representative. 6. Water leaking along pump shaft. 7. Timer display lights with set time, but pump does not start when START/STOP activated. 8. Pump always on while power applied to system. 9. Pump running slow and erratic with growling noise. 10. Timer sets time and counts down, but pump will not run. 1. Defective timer. Check with volt meter. Increase size of supply wire. Report low supply voltage to power company. Voltage at motor must be within 10% of motor nameplate voltage during operation. Disassemble pump and replace seal. Replace circuit board. 2. Faulty timer cable. Replace cable. 3. Faulty re!ay. 1 Defective relay (lOW or no v?~tage at rel~y input). Low voltage to pump from high voltage side of relay. Replace relay. Replace relay. 2. Short in timer cable. Replace cable. Replace relay. 1. Worn pump seal. 1. Relay defective. Check voltage at pump. Replace relay if less than line voltage. - _. - - 5 TROUBLESHOOTING (Continued) .. - SYMPTOMS ~- PROBA BlE CAUSES RECOMMENDED ACTION ~. 11. Pump runs and trips GFCI breaker. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 12. Whirlpool starts itself. 1. Bad bearing in pump. Replace pump. 2 Loose electri cal connections. Secure all contacts. 3. GFCI trips at less than 5 milliamperes Replace GFCI breaker. 4. Ground fault in system. Disconnect wires from relay. Check resistance between case and terminals. If below 100 kilohms, replace relay. 1. Not on a separate circuit. Wire electrical supply on separate circuit. 2. Power outag e, lightning voltage Replace 60347 printed circuit board. spike, transi ent noise. 13. Whirlpool timer flashes "L" when START/STOP pushed. ._- .... 14. No display/timer dead. 3. Contaminants (sawdust, metal shavings) on 60347 timer board. Clean or replace 60347 printed circuit board. 4. Faulty relay. Replace relay. 1. Water in tub not 2" above jets. Add water. 2. Three-hole retainer in jet assembly in wrong location. See trim kit installation instructions. 3. Air lock in breather. Clean breather orifice and observe water to fill up into clear tube equal to water level in tub. 4. Obstruction in line from threehole retainer to float control. Remove cover of float control and run wire to orifice hole in jet assembly. 5. Failure on 60 347 printed circuit board assem bly or in timer cable. Disconnect float control plug from power pack. If timer still flashes "L", replace 60347 timer board. Also check control cable for nails . 1. Face plate n ot making contact Masonry box not flush with finished wall (see installation instructions for 60350 timer). ~ with foils for set time and STARTiSTO P. 2. No output 0 n secondary side of Replace transformer. transformer (6-14VDCi. 15, Timer LED missing legs. 3. Timer cable connection loose or Secu re connection or replace damaged at timer prongs. 60318 timer cable. Replace timer 60347 printed circuit 1. Timer circuit ry defective. board. ~~~- 16. Whirlpool flashes "L" with tub full. 1. Three-hole retainer in jet assembly in wrong location. See trim kit installation instructions. 2. Water level sensor float Invert float. reversed. 17. Whirlpool does not flash "L" with tub empty. 1 Level float pi ug disconnection. 18. Pump runs but no whirlpool action. 1. Brass orifice s missing behind jet assembly. Insure connection. ~------ - - - - ~~.~ Install orifices. 2. Suction bloc ked._ _ _ _ _ _-'C:'I"'e"a"rsucti":'o"n.'-_ _ _ __ 6 COMPONENT IDENTIFICATION LIST 5_ , 1 , (' 2 ~ 00 7 8 • ~ Item No. 1 2 3 4 Description Timer Power Panel Water Level Control Motor and Pump .- Depends on model Quantity Item No. Description Quantity 1 1 1 1 5 Adjustable Air Control Adjustable Jets Water Suction Inlet Timer Cable 2 6 7 8 1 1 Figure 2-2. Whirlpool Bath Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 • 7 Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 SECTION 3- TIMER THEORY OF OPERATION Power for the timer (Fi Q Ure }.-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. 5 sw, ., ~ :fLi ~5 ~ ,~,::k.~ T. White Red Green Power Panel - 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. Figure 3-1. Timer Board 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. Tub Model K-783 Old Timer 9680/81 K-792 9680/81 K-802 9680/81 K-1409 9680/81 K-784 9680/81 K-1402 9680/81 K-1410 9680/81 K-1422 K-1482 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. K-772 New Timer 60350 60350 New Power Old Power Panel Panel - 60300 60300 60350 60350 60350 60233 60101 60101 60233 60229 60350 60300 60300 60300 60325 60350 60300 60229 60350 60350 60350 60325 - 60102 60325 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. 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. 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 I, I:] IL o ----, 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 90 0 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. 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. 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 timer installation procedures. 1. Remove four screws from faceplate of old timer. COMPONENT IDENTIFICATION LIST Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 4 y. r ----......... Wl 0 0 00 ~ ,,~, 3 ~ "-- 5 ~- "'--. Item No. Description Quantil}!' Item No. Description Quantit}!' 1 2 3 Masonry Box Timer Cable Timer Circuit Board 4 1 1 5 Machine Screw Control Plate Gold-Chrome Insert 4 1 2 6 Figure 3-4. 60350 Electronic Timer 10 2 ---- ~-..:.-:::::..- c ~ SECTION 4- POWER PANEL THEORY OF OPERATION Replacing the Transformer 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. 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. When the relay is closed, 3 to 5 VDC can be read across contacts E and F. 4. Remove transformer. 5. Replace in reverse order. Make sure all connections are secure. Aschematic of the power panel is shown in Figure 4-1. SERVICING THE POWER PANEL Replacing the Relay 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): 1. Remove power panel cover by removing four screws. 2. Mark and remove all leads attached to relay. CAUTION: Turn Whirlpool Bath circuit breaker OFF or otherwise disconnect power from unit before performing any maintenance on power panel. 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. Use a multimeter to check power before replacing any components. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 J - - - - - - --I , :;~qD~== L~;' ~ SEC'~" '''v.,-----',~ L.evel Sw. ~. I PRIMARY 12.0", r~1 III I To Molor -~ F c Figure 4-1. Power Panel Schematic 11 COMPONENT IDENTIFICATION LIST Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 Item No. Description Quantity Item No. 1 2 3 4 Electrical Box Electrical Box Cover Electrical Box Gasket Machine Screw Receptacle Machine Screw Transformer 1 1 1 4 1 4 1 8 9 10 11 12 13 14 5 6 7 Figure 4-2. Power Panel 12 Description Wiring Harness Relay Wiring Harness Hanger Machine Screw Bushing Machine Screw Quantity 1 2 5 2 2 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 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 Bracket /' Breather Valve // Jet Assembly (Inside Tub) \ ___ Flexible Plastic Tubing Float Chamber A-I[--</ ....mblY Copper /' ~. /~~>// rr~/ Tubing Waler Level Inlet '==~ ~'--<ll WlJ/ III ( V Power Figure 5-1. Water Level Control 13 2. Disconnect flexible plastic tubing from float chamber assembly. COMPONENT IDENTIFICATION LIST 3. Remove breather valve and flexible plastic tubing. 1_~ 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. 2-'~ Float Chamber Assembly U 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. , , 2J '---....0 -------t:) 3. Remove two screws securing float chamber assembly to harness bracket. 4. Remove flexible plastic tubing connecting breather valve to float chamber assembly. 6 , 5. Remove float chamber assembly. '''et /' 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 14 Item No. Description Quantity 1 2 3 4 5 Breather Valve Flexible Tube Spring Clip Level Switch Sub Assembly Gasket Float Float Chamber Sleeve 1 1 1 1 1 1 1 1 6 7 8 Figure 5-2. Water Level Control Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 SECTION 6- MOTOR AND PUMP THEORY OF OPERATION 4. Remove motor and pump. The motor and pump work as a unit; the motor provides the drive power for the pump impeller. S. Disconnect motor power cord from power panel. 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. 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. SERVICING THE MOTOR AND PUMP 2. Lift off diffuser and gasket. 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: 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. 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 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. Air/Water Mixture CAUTION: When installing seal assembly members, do not use a screwdriver or other sharp object which may damage ceramic ring. Figure 6-1. Water/Air Mixture 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. and pump can be disassembled for service using the following procedure (refer to Figure 6-3): 15. Ensure grooved portions of rotating member are located over raised portions of impeller shaft 1. Remove screws secunng pump casing to face plate. Remove casing. 16. Hand tighten impeller onto motor shaft. 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 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. 3. Rotate impeller counterclockwise and remove. 4. Slide rotating member of seal assembly off impeller shaft. 5. Remove face plate O-ring. 6. Remove face plate from motor housing. ITT MARLOW 60186, 60187, 60478, 60479, 60660-M,60661-M,604S7,60S01,60662-M ANO 60663-M MOTOR ANO PUMP 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. The ITT Marlow60186, 60187, 60478, 60479, 60660-M, 60661-M, 60457, 60501, 60662-M and 60663-M motor 8. Check impeller, O-ring and seal assembly. If any item is damaged or worn, replace it. Impeller and 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 12 9 5 • 3 Item No. Description Quantity Item No. 1 2 3 4 Casing Gasket Diffuser Impeller Seal Assembly Gasket Screw 1 1 1 1 1 1 4 8 9 10 11 12 13 5 6 7 Figure 6-2. Motor and Pump 16 Description Lockwasher Seal Plate Screw Slinger Motor O-Ring Quantity 4 1 8 1 1 1 COMPONENT IDENTIFICATION LIST ITT Marlow 60186, 60187, 60478, 60479, 60660-M, 60661-M, 60457, 60501, 60662-M and 60663-M Molorand Pump Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 8 , 1 7 ---- ~ 4 3 --~ Item No. 1 2 3 4 Description Quantity Item No. Description Quantity 1 6 1 1 5 Seal Assembly Face Plate Slinger Motor 1 1 1 1 Casing Screw O-Ring Impeller 6 7 8 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. 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. 14. Ensure grooved portions of rotating member are located over raised portions of impeller shaft. 6. Remove screws securing seal plate to motor housing. 15. Hand tighten impeller onto motor shaft. 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. 16. Install O-ring on face plate. 17. Replace pump casing and secure in place. 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. CAUTION: When installing seal assembly members, do not use a screwdriver or other sharp object which may damage components. 11. Install slinger on motorshaft. Ensurethatflange of slinger is facing threaded end of shaft. 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. 12. Install D-ring on ceramic seal member. Ensure it is properly seated. 17. Slide rotating member of seal assembly onto impeller shaft. Lubricate with clean water only. 13. Press ceramic ring into clear plastic retainer. 18. Hand tighten impeller onto motor shaft. 14. Attach seal plate to motor housing. 19. Install D-ring on seal plate. 15. Install D-ring on cut ridge of clear plastic retainer. 20. Replace pump casing and secure in place. 10. Clean impeller hub and all seal cavity surfaces. COMPONENT IDENTIFICATION LIST Hayward 60660-H and 60661-H Motor and Pump Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 , e?~1 Item No. 1 2 3 4 5 6 7 Description Screw Casing D-Ring Impeller Seal Assembly Seal Plate Slinger Quantity Item No. Description Quantity 6 8 9 10 11 12 13 Motor Screw End Cap Insulating BUShing Insulating Bushing Nut 1 4 1 2 2 1 1 1 1 1 Figure 6-4. Motor and Pump 18 6 • Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 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): 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. Air Control Assembly 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: 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. Whirlpool Model GuardIan K-783-S, Steeping Bath K-792-S, Caribbean K-802-S, Barbados K-1409 Guardian K-784-S, Barbados K-1410 The Super Bath K-1422 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. . Infinity'~ 00 K-1482 - Location of Jet Housing With Three Holes· Left Rear Right Rear 1st Jet Housing Clockwise From the Drain 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. 1 Remove screw securing suction hood and screen to inlet housing. 14. Tighten screws until ball moves freely with slight side to side pressure. 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. Suction Inlet The water suction inlet is serviced using the following procedure (refer to Figure 7-1): 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. Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 COMPONENT IDENTIFICATION LIST .--::::.-. Item No. Description Quantity 1 2 3 4 Control Knob O-Ring Trim Cap Setscrew O-Ring Screw Retainer 2 2 2 2 4 2 1 5 6 7 Item No. 8 9 10 11 12 13 14 Figure 7-1. Trim Kits 20 Description Quantity O-Ring Directional Ball Insert Beari ng Trim Ring Screw Suction Hood Hair Screen 1 1 1 1 1 1 • SECTION 8- INFINITY BATH FAUCET FITTINGS COMPONENT IDENTIFICATION LIST Guillen's Enterprises, inc '_~ ) ~:;..,-:Original Kohler Parts guillens.com 800-222-7855 '-0 '--1 4_~ -,-- '-@ I (4~ , __ L_ ------------ Item No. 1 2 3 4 5 6 7 8 9 10 11 Description Cap O-Ring Screw Handle Lock Ring Bonnet O-Ring O-Ring Washer Stem Plunger with Seat Washer and Screw Quantity Item No. 2 2 2 2 2 2 12 13 2 2 2 2 2 14 15 16 17 18 19 20 21 22 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 Figure 8-1. Faucet Fittings 21 COMPONENT IDENTIFICATION LIST r -- _ Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 ' ____ 3 ') I /' 2 I,.,c IIi. r ) 1, ~ I ,- l' , 6 1 1- J 16-...... ---- Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Description Screw Hood Nut Lift Rod Quantity Item No. Description Quantity 2 1 1 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Ell & Tube SA Nut 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Lift Rod Safety Rod Nut Washer Link Spring Nut Gasket Clamp Tube Clamp 1 1 1 1 1 1 1 1 1 1 Figure 8-2. Drain FIttings 22 Gasket Tee Gasket Nut Drain Ell & Tube Gasket Strainer Lift Toggle Nut Stopper O-Ring Tailpiece SECTION 9- OLD STYLE TIMERS AND POWER PANELS t50~" "O~, 'e, ! ------Tl • _0 , , '., ~ '" .''4.. , I " Ie .,.'" : . I ... ... " I , "I.~'" I '~"'~~7. , • '. L" ~ l ,0, ----! I j ; ~ .1 , ,. ~ M "i I ' ~ , ~ N '" _ ... •• '".tit. ' ~t ..". .. .. t~'" . .. '~J • , , l; " I " '" " 0 I', ~ '. $" .-., "'1 r '1 . I~-" ¢' "'Mrl' ;! ,,1,,' .. • I~. ~ , I " ~ yo ,, ~ @,.co. ., H M'" ,--Tl,.. ... ""''" " ~ '" e (. ~ " . L:.; .. . .. le- l---=:J'J'q ' U" ' Vl'---------'" ".'~~. I I '" . " y"~"~.'8 ~ VO~ ~,...~ur"c~ i---T! , , ,e ~ M "1.1"'0 "'01.<'07 :l<.JMprR , " , , = ®<~;J; '0 "' 'M : . ,.-",.., ~. ,,~, -, 'M < • '" .0" ~ CQM .. " ... <!,.---- Agure 9-1. 9680 Non-LC~ Timer Schematic Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 23 -- ,. ",,-S,s,.""'''' "'''". .. M, ,'" •• ' ,'',:'0'''.' ''''' 1 + IO .. ~...{I0 . . "' "' '-.0' " ,." " ' H " eo e, e, ' "" 10 p,~ "''' , "u,.w "'.... ,., .. 'O~ ,~ .. , ..- ,,' "OD"''' .,;.,,1 ".;-", ;..~,-, ".; L "';. ... ~C" "'C'w ~ I MFl:; '-<C. .. t l l """ O. J -.. ~'Q"" ,. c,Ct;>""-" "'~ j .... I I~O" Y"W '''''- ""S """k,,""""''''' 1 r ,-"-,,.,,,,, WI~'"'' 0' .'",FC"'V " _Iuf~!>" C4 --- "-"'''-'''''- """"~D " ~,~ "'''. -- , .- ." ", - .. " DI ""'"'"",,"' "',a"'~, ,.,.~ , 00 sc TR-""5""""'S "'~ "t, Q~ " """'i ..,""-u ~"o~ ~..., Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 .... "'." ...,....,,'" ""'"ff .oJD, "' .. ~ "'-, MC,~- .. liD. N'~" Cb_</~,o_e" <. ,~5 CA- "",',er 1<-. Co """"" ..." Z~"U I) f)'ODC _1m;" -.;;;, ,;. _ [f) Figure 9-2. 9680 Non-LCD Timer Component Diagram 24 3."_,<><0 ... , I1 r"t:t ,. " ~ ,'" I '''' • ~ ~"~"<4UC'" j";L"""'.JUIoI_ ~I------- '''''''' I , .. I " , I I Figure 9-3. 9681 LCD Tlmer Schematic Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 25 -. ... c~ "..., aF ~._"". ~O>, TC,..,.1A'i4 "'. I .", 0'0 ~'.' T" H .. 0' 0' 0' OP,."rr~·'-'''''' TPU ,,,. , " . " . ' . . , , ,""" '''''''''-'' ~,. .. "', "" -", 0, 00 .. '0/(1<,"',,,,, " '''''~ .,." Y;w o~ ~, , 'O __ "WIC . . , 0" '" IO~ r." -...". - _ ",DD~"" ,vD. ~ -.. "W ,.0" 0, 9/</ j.u ., 0, ...... .. ,0 ,0 I I -' C-<P~C.''''<>R~ V~LU'" ""''''' ", " ~ -.' -. -.. --.... 'of ~5" " T~I="'"" '0 "'''-'.3~D~ ".u ...~~ ..... 00 '''',.,....,.,00''''''''' IC-' , "' ". ""'-,~ ~-~~-".- '<-5 ¢Jo. ~"". ~...- '"' CD- ,~-, ". ~,>,,, "' ~D-"'~~·8. ~."'u ~ _~~"" '''.~ Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 ~" .., P,ON ,"v "~_ F " Figure 9--4. 9681 LCD Timer Component Diagram $, II~ '" n ;::r,", ! ~~~ I 1~1,t i ,~! "l IC~",,, :~ -,0, '? I R L_ ,'~ " ~ -- ~.~ "f-ii f' - - - - - - - - --- , -II 'f vo .. ~ .. ""'" "~,,,,',., "~Q'~ ," ". ® ~~';'; ~~';;:,,~'~ ~:"~d':'~~M .".~ ",,, ~ -- {" WH' _ _ _ ~ " u " - {TO MOTOR ,,~,- Jf'''- ~ Figure 9-5. 9680/9681 Tlmelll - Power Panel Wiring Diagram 26 LINE <'- ""'U~I~Y'llU £uc<""-v~ 1><: ..."y ~7~"7,,,~ ~ --~ .,..,...."",.a ,,7~"'~"'" <IAIOa>W~"CR~ P<""F?""_~ q.!Hl"'~ p "/~~ lin",·", ~~E. ".$",-" ,>IJ ",,001 7°/_1/. ~ ~M-""~'1't" .... c ,. "M~ Figure 9-6. 9680/9681 Time rs - Power Penel Schemellc . 'f'l" '" '""'- 'i' ~ ,,~, Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 .ft~O ,e, ";;,, r'i- ~/ -"" , , d ~ 0-<l , ,, ,, ' ~ we " D2~K~ ~K e,S$R 1 ~" , ~~'F so. '" , '" ~ • ~I I " I y~; , , , , " ~ ~ ~ ~ ~ Figure 9-7. 9680/9681 Timers - Power Panel Com ponents Diagrams 27 Guillen's Enterprises, inc Original Kohler Parts guillens.com 800-222-7855 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