K-705764 - Shower system KOHLER - Free user manual and instructions

USER MANUAL K-705764 KOHLER

K-705727, K-705728, K-705729,

K-705736, K-705737, K-705738,

K-705739, K-705740, K-705741

M product numbers are for Mexico (i.e. K-12345M)

Silicone Sealant Masking Tape Tape Measure Level [4' (1.2 m) to 6' (1.8 m)] Center Punch File Drill and Assorted Bits Claw Hammer Pencil or Felt Tip Marker Assorted Screwdrivers Knife Miter Saw or Hack Saw with 32 Teeth Per Inch Blade Plus: • Drop Cloth • Tile or Masonry Bit (if installing onto tile walls) Safety Glasses 1/4" and 5/32" Hex Wrenches Miter Box Caulk Gun Pliers

Before You Begin

WARNING: Risk of serious injury. Damage prior to installation can result in glass shattering. Inspect the glass and all parts for damage before installation.

WARNING: Risk of serious injury. Improper installation can result in glass shattering. Follow all installation instructions.

NOTICE: Do not touch the edges of the tempered glass with tools or any other hard objects. Do not set the unframed tempered glass directly on the floor or any hard surface.

WARNING: Risk of serious injury. Do not cut tempered glass. Tempered glass will shatter if cut.

WARNING: Risk of serious injury. Shower door and side panels can shatter. Regularly inspect the glass and all parts for damage, missing, or loose parts.

IMPORTANT! Leave this manual for the end user. Read these instructions before installing or using this product.

CAUTION: Risk of product damage and property damage. This shower door is very heavy. Do not install it to plastic shower modules or drywall unless additional support is provided behind the wall.

IMPORTANT! Record the model numbers from each box and the master model number on the Homeowners Guide if you intend to save it, or in your records for later use. The numbers can be found on the label, starting with a "K-". The proper model number will enable our customer service representatives to quickly help you if needed.

☐ Your new Kohler door can be installed with the door opening to either the right or left. Install the door with the pivot side away from the showerhead for best results. These instructions show the door installed with a left side swing. Doors that swing to the right would be opposite.
- Handles are purchased separately. Install the handles following the installation instructions provided with them.
☐ These instructions cover both 30" (76.2 cm) to 48" (121.9 cm) and 60" (152.4 cm) models. Some steps may pertain to only one model. Make sure to follow the steps for your model of door only.
Before starting the installation, lay out and identify all of the parts. Inspect them for damage.

Before You Begin (cont.)

☐ Some steps in these instructions are specific to a right or left side hinge installation. Follow the instructions which pertain to your installation configuration.
Place a drop cloth in the bottom of your shower to cover your drain and ease clean-up.
□ Closely follow the instructions pertaining to the sealant application on the door. Sealing areas other than those shown may cause leaking.
□ Two people should perform this installation.
☐ Kohler Co. reserves the right to make revisions to the design of products without notice, as specified in the Price Book.

60" (152.4 cm) Models Gasket Wall Bracket Top Right/ Bottom Left Shim (if needed) Strike Lite Glass Panel Glass To Glass Seal Glass Door Panel Movable Hinge Top Left/ Bottom Right Cover Back Plate Bushing Weld Nut Wall Jamb Gasket Wall Bracket Top Left/ Bottom Right Gasket Shim (if needed) Glass Panel Side Lite Glass Panel Cover Back Plate Threshold Seal Strike Lite Filler Wall Bracket Bottom Right/ Top Left Shim (if needed) Gasket Bottom Track VHB Foam Tape Side Lite Filler Movable Hinge Bottom Left/ Top Right

Parts Identification

48" (121.9 cm) Models and Smaller

Fixed Hinge Top Left/ Bottom Right Screw Wall Bracket Top Left/ Bottom Right Gasket Shim (if needed) Wall Jamb Shim (if needed) Wall Bracket Bottom Left/ Top Right Screw Fixed Hinge Bottom Left/ Top Right Screw Back Plate Gasket Side Lite Glass Panel Cover Back Plate Glass Panel Gasket VHB Foam Tape Side Lite Filler Weld Nut Strike Jamb Cap Glass Door Panel Screw Strike Jamb Anchor Strike Jamb Seal Threshold Seal Bottom Track Movable Hinge Bottom Left/ Top Right

Parts Identification (cont.)

Top View Swing open toward right

Note: Images are for reference only. Not actual product.

Top View Swing open toward left

1. Determine the Door Configuration

IMPORTANT! Install the pivot side of the door on the side opposite the showerhead for easy access to shower controls.

□ Determine whether the door will pivot on the right or left side.
□ Make sure the door can swing freely in the chosen configuration.

Measure here. Angled Base Measure distance "D" above curves in the corners. D Measure here. Curved Base

Important: Measure carefully. If your walls are curved or angled, measure above the curve or angle. Failure to do so can result in an improperly cut bottom track.

2. Measure and Cut the Bottom Track

CAUTION: Risk of personal injury. Always wear safety glasses while cutting.

NOTE: When using a retractable case tape measure, add the length of the case to the measurement or measure in a manner that excludes the case.

☐ Measure from wall to wall at the bottom of the shower door opening. This is distance "D".
☐ Subtract 1/16" (2 mm) from distance "D." The resulting dimension is the bottom track cut length.
□ Mark the bottom track at the determined distance.

NOTE: For best results use a miter box and 32-tooth per inch hacksaw to make the cut.

□ Cut the bottom track at the mark.
- File the rough edges smooth where the bottom track was cut, taking care to avoid damaging finished surfaces.
☐ The cut bottom track should sit flush on the threshold without hand pressure or tape to hold it down.

Side Lite Filler VHB Foam Tape Bottom Track Inside of Shower 1" (2.5 cm) Min VHB Foam Tape Groove Slanted Section 3/8" (1 cm)

3. Locate the Bottom Track

NOTE: When installing a 60" (152.4 cm) door, the hinge side lite is the narrow piece of glass with 4 holes in it.

☐ Cut length of the supplied VHB foam tape to match the width of the hinge side lite (if necessary).
☐ Remove the backing from the tape and, starting adjacent with the end of the track on the hinge side, apply the tape to the flat top of the bottom track. Position the tape about 3/8"(1 cm) from the groove in the bottom track, centered on the flat portion of the bottom track.

NOTE: Position the bottom track far enough toward the outside (dry side) of the shower threshold to allow the strike jamb or strike lite filler to sit behind the bottom track. The back edge of the bottom track should be at least 1" (2.5 cm) from the inside edge of the shower threshold to allow the rest of the door to sit on the threshold.

☐ Position the bottom track on the threshold with the slanted section toward the inside (wet side) of the shower.
☐ Make sure the front edge of the bottom track is an equal distance from the front edge of the shower ledge at all points.
☐ Temporarily secure the bottom track to the ledge with masking tape (do not apply the tape over the VHB foam tape).
☐ Mark the location of the bottom track with a soft pencil.
☐ Position the side lite filler over the VHB foam tape and install it into the groove in the bottom track.

6' (1.8 m) Level Draw a line up the level. Pencil Side Lite Filler Pencil Pencil Pencil Shim (if necessary) Mark the location of four "L" bracket mounting holes. Screw Drilled Holes Shim (if necessary) "L" Bracket for Top Left or Bottom Right "L" Bracket for Bottom Left or Top Right Stud Stud

4. Install the Hinge-Side L-Brackets

IMPORTANT! The L-brackets are installed against the hinge-side wall on 30" (76.2 cm) to 48" (121.9 cm) models. 60" (152.4 cm) models have an additional set of L-brackets on the strike side. Their proper installation is critical to the rest of the installation.

☐ Choose the correct L-bracket based on the door swing configuration (see "Parts Identification") and position the bottom of the L-bracket on top of the bottom track. Make sure the L-bracket is aligned with the side lite filler.
□ Use a level to align the L-bracket vertically. Mark the center of the slotted hole locations.
- Remove the bracket and set it aside. Drill the holes following the "Drilling Instructions" below.
□ Place the hinge side wall jamb on top of the bottom L-bracket.
□ Use a level to align the hinge side wall jamb vertically.
□ Temporarily secure the hinge side wall jamb to the wall with masking tape.
□ Position the top L-bracket on top of the hinge-side wall jamb.
□ Use a level to align the L-bracket vertically and mark the hole locations with a pencil.
- Remove the hinge-side wall jamb and bracket from the wall and set aside. Drill the holes following the "Drilling Instructions" below.

Drilling Instructions

NOTE: When the installation is on ceramic tile, use the center punch to nick the surface glaze or drill a very small pilot hole. Tap the punch lightly with the hammer to avoid cracking the ceramic tile.

□ Lightly center punch the hole locations or drill very small pilot holes.

NOTE: Start drilling slowly to prevent damage.

□ Use a 9/64"bit to drill a hole at each of the marks, and thoroughly clean the shower ledge.

□ Position a level vertically against the hinge-side wall. Hold the level in a plumb position.

☐ If the wall is out of plumb, use a provided shim behind the L-bracket to bring it plumb.

☐ Attach the L-bracket to the wall with the supplied #8-18 x 2" screws. Use shims as necessary.

Side Lite Screw Bushing Gasket To Inside of Shower Bottom Fixed Hinge

5. Install the Bottom Bracket

NOTE: There is a label on the side lite panel identifying the "non-coated side" of the panel. The non-coated side of the panel should face the outside of the shower when bottom bracket is being installed.

Place a bushing in the lower hole in the side lite panel where the bottom fixed hinge will be installed.
☐ Place the gasket on the lower corner of the glass, aligning the hole in the gasket with the hole in the glass.
☐ Gently slide the bottom fixed hinge over the gasket, aligning the hole in the bracket with the hole in the glass.
☐ Insert the supplied screw into the side of the bottom fixed hinge and fasten.
□ Tighten the screw until is it snug and/or flush with the surface. Do not overtighten.

Apply Silicone Sealant. Side Lite Filler Outside Plate Bushing Gasket "L" Bracket Wall Jamb Screw

6. Install the Side Lite Glass Panel

CAUTION: Risk of injury or product damage. Unframed tempered glass should not contact hard surfaces or it may shatter. Do not touch the edge of the tempered glass panel with tools or any hard objects. Do not set the unframed tempered glass edge directly on the floor.

☐ Place a bushing in the remaining bottom hole of the side lite glass panel.
□ Place the gaskets over the edges of the side lite panel.
□ Using your hands, place the wall jamb on the edge of the side lite glass panel, opposite the attached hinge and exactly in the middle of the vertical edge of the side lite.
- Important! Apply a bead of silicone sealant to the groove of the side lite filler.
□ Place the side lite glass panel onto the pins of the L-brackets.

IMPORTANT! Make sure the glass panel is as close to the wall as possible while still remaining plumb.

☐ Place the outside plates onto the pins of each of the L-brackets and securely fasten with the supplied screws.
□ Wipe off excess silicone sealant.
☐ Position the bottom hinge bracket parallel with the bottom track. Use a level to align the front face of the bracket with the front face of the bottom track.
☐ Temporarily attach the bracket with masking tape or a clamp, making sure there is no gap.
☐ Insert the self-tapping screw into the hole of the bottom hinge bracket and carefully thread the screw into the bottom track (do not overtighten or it may strip the screw.)
□ Remove any visible aluminium chips.
☐ Insert one of the hinge pins completely into the bottom hinge bracket.

Glass Door Panel Lower Hinge Bracket (gr groove aligns with edge of glass panel) Weld Nut Bushing Inside of Shower Screw Back Plate Screw

7. Assemble and Attach the Hinge Jamb

CAUTION: Risk of injury or product damage. Unframed tempered glass should not contact hard surfaces or it may shatter. Do not touch the edge of the tempered glass panel with tools or any hard objects. Do not set the unframed tempered glass directly on the floor.

NOTE: Make sure you choose the correct hinge bracket. The weld nut groove should point towards the near edge of the glass.

☐ Slide two weld nuts into the groove of the lower hinge bracket and space them so that they align with the holes in the door panel.
☐ Insert a bushing onto each weld nut.

NOTE: There is a label on the door panel identifying the "non-coated side" of the panel. The bracket should be located on the non-coated side of the door panel.

☐ Position the bracket on the door panel so that the weld nuts pass through the two holes in the door panel.
☐ Position the back plate on the opposite side of the door panel, so that it hooks into the bottom of the bracket.
☐ Insert a screw into each of the two weld nuts through the slot in the back plate and tighten firmly. Do not overtighten.
□ Repeat this procedure to install the top hinge bracket on the door panel.

Strike Jamb Screw Anchor Strike Jamb Threshold

☐ Position the strike jamb on the opposite wall, tight to the inside edge of the bottom track, resting directly on the threshold.
□ Use a level to align the strike jamb vertically.
□ Temporarily secure the strike jamb to the wall with masking tape.
□ Mark the hole locations with a pencil.
□ Remove the strike jamb and set aside.

NOTE: When the installation is on ceramic tile, use the center punch to nick the surface glaze or drill a very small pilot hole. Tap the punch lightly with the hammer to avoid cracking the ceramic tile.

□ Lightly center punch the hole locations or drill very small pilot holes.

NOTE: Start drilling slowly to prevent damage.

□ Use a 9/64"bit to drill a hole at each of the marks.

□ Thoroughly clean the shower ledge.

☐ Attach the strike jamb to the wall with the supplied #8-18 x 1-1/2" screws.

☐ Insert the strike jamb cap into the strike jamb from the top.

☐ Insert the bulb seal into the strike jamb from the top.

Strike Lite Glass Panel Wall Jamb Screw Outside Plate Bushing Gasket "L" Bracket Strike Lite Filler Apply Silicone Sealant. Strike Lite Filler

9. Install the Strike Side Glass Panel - 60"(152.4 cm) Models

CAUTION: Risk of injury or product damage. Unframed tempered glass should not contact hard surfaces or it may shatter. Do not touch the edge of the tempered glass panel with tools or any hard objects. Do not set the unframed tempered glass directly on the floor.

☐ Insert the strike lite filler into the bottom track.
☐ Install wall brackets following the steps in the "Install the Hinge-Side L-Brackets" section, using the strike lite filler to position the lower wall bracket.

NOTE: There is a label on the strike side panel identifying the "non-coated side" of the panel. If the strike panel is coated glass, the side of the glass with the "Non-coated side," label should face towards the outside of the shower.

☐ Carefully place the wall jamb on the edge of the strike lite glass panel, opposite the attached hinge and exactly in the middle of the vertical edge of the strike lite glass panel.
□ Place a bushing in the bottom hole of the strike lite glass panel.
☐ Position the gasket over the edges of the strike lite glass panel, with the top holes aligned with the bushing.
□ Apply a bead of silicone sealant to the groove of the strike lite filler.
☐ Align the bushing with the pin on the "L" brackets and position the strike lite glass panel on the strike lite filler with the pins of the L-brackets through the bushings.

IMPORTANT! Make sure the glass panel is as close to the wall as possible while still remaining plumb.

☐ Place the outside plates onto the pins of each of the L-brackets and securely fasten with the supplied screws.
□ Wipe off excess silicone sealant.
☐ Install the glass to glass seal on the edge of the strike lite glass panel. Position the triangular protrusion on the back side of the seal so it is aligned with the edge of the glass.

Top Fixed Hinge Screw Gasket Bushing Hinge Pin

10. Install the Door

NOTE: The door may require adjustment; do not make final adjustments until the header and handle are installed.

CAUTION: Risk of injury or product damage. Unframed tempered glass should not contact hard surfaces or it may shatter. Do not touch the edge of the tempered glass panel with tools or any hard objects. Do not set the unframed tempered glass directly on the floor.

IMPORTANT! Perform the following steps with two installers.

Place a bushing in the upper hole in the side lite glass panel where the top fixed hinge will be installed.
☐ Place the gasket over the top corner of the side lite glass panel so that the hole in the gasket aligns with the hole in the glass.

Installer #1

□ Lift the door into a position so that the hinge pin is above the fixed hinge.
- Carefully lower the door so the hinge pin fits into the bottom hinge. Hold the door in place while installer #2 installs the top fixed hinge.

Installer #2

□ Place the top fixed hinge over the gasket of the side lite glass panel and hinge pin.
□ Align the hole in the top fixed hinge with the bushing and carefully position the top fixed hinge on pin.
☐ Insert the large diameter screw through the bracket into the bushing and tighten until flush with the surface. Do not overtighten.

Hinge 5/32" Hex Key Screws

11. Adjust and Secure the Door

CAUTION: Risk of injury or product damage. Unframed tempered glass should not contact hard surfaces or it may shatter. Do not touch the edge of the tempered glass panel with tools or any hard objects. Do not set the unframed tempered glass directly on the floor.

CAUTION: Do not allow the edges of the glass panel to contact the bottom track, or the seals. Contact may shatter the glass or tear the seals.

□ Install the handles following the instructions packed with them.
□ Align the door with the strike lite glass panel.

IMPORTANT! Only loosen the screws enough for the door panel to move. If the screws are loosened too much the weight of the door may pull the hinge and back plate apart. (If the hinge and back plate pull apart, lift the door to remove stress and re-tighten the screws.)

☐ If the door needs adjusting, loosen the screws located in the hinges (do not remove) one bracket at a time and adjust the panel as needed.
☐ When the door is properly aligned the bottom edge of the glass should be parallel with the bottom track.
☐ When the door is properly aligned, fully tighten the screws. Do not overtighten.

Trim the seal at the hinge bracket so door opens without snagging the seal. Threshold Seal Bottom Track

Strike Jamb Seal Trim around strike seal.

12. Install the Bottom Track Seal

CAUTION: Risk of product damage. Do not install the threshold seal under the hinge or the door will not operate properly.

NOTE: If needed, apply a small amount of water or petroleum jelly to lubricate the seal when sliding it into place.

□ Starting at the strike jamb side, install the threshold seal into the groove of the bottom track.
□ Position the seal so it is even with the end of the track.
☐ Notch the foam portion around the strike jamb on 30" (76.2 cm) - 48" (121.9 cm) models or the glass to glass seal on 60"(152.4 cm) doors.
□ Carefully trim the excess seal at the door hinge with a scissors or knife, confirming that when the panel is opened/closed the hinge does not snag the seal.

13. Finish the Installation

□ Slide the hinge covers over the back plate of the top and bottom door panel hinges.
- Remove all temporary masking tape from the bottom track.

IMPORTANT! Carefully follow the silicone sealant manufacturer's instructions for application and curing time.

NOTE: Thoroughly clean and dry all dust, dirt, and grease from the bottom track and shower ledge surfaces where silicone sealant will be applied.

NOTE: Placing a small weight on the bottom track to hold it flush to the track while the sealant cures can help.

□ Use masking tape to protect areas adjacent to those where the sealant is being applied.
□ Apply sealant to the outside of the shower where the bottom track meets the threshold.
□ Apply sealant to the outside of the area where the wall jambs and brackets meet the walls.
- Allow the sealant to fully dry before operating the door. Refer to the sealant manufacturers instructions for recommended curing time.

Technical line drawing of a door frame with handlebars and railings (no text or symbols)