sapphire round corner sliding shower door

SAPPHIRE ROUND CORNER
SLIDING SHOWER DOOR
INSTALLATION GUIDE
CAUTION
It is the responsibility of the INSTALLER to ensure that the
installation complies with council and or local authority bylaws.
Instructions, drawings, and diagrams contained in this manual
present information available at the time of printing. Although
every attempt has been made to keep them up-to-date, Kohler
Company reserves the right to implement product changes
without further notice.
1089610 - C May 2009
Page 1
Kohler Co.
BEFORE YOU BEGIN
Before you install your shower door, please
read these instructions carefully to familiarise
yourself with the required tools, materials and
installation sequences.
These instructions contain important care and
cleaning information. Please leave these for the
consumer after installation.
Make sure that the shower tray and the wall
are completely finished prior to installing your
SAPPHIRE shower door.
CAUTION: Risk of injury or product damage.
Tempered glass cannot be cut.
CAUTION: Before commencing installation.
KOHLER strongly recommends reading these
installation instructions.
ATTENTION:
Please install this door on an ENGLEFIELD
Quick-Fit® shower tray only.
IMPORTANT:
The shower door requires a flat and vertical
wall surface. The flatness is recommended
to be out by no more than 4mm / m.
TOOLS AND MATERIALS REQUIRED
Tools Required.
Philips Screwdriver.
Pencil.
Silicone gun.
Measuring tape.
Safety glasses.
Center punch.
Hammer.
Knife.
Drill bits. 1 x 6mm. 1 x 2.5mm.
Level.
Materials Required.
Drop cloth.
SIKA Silaflex NG silicone sealant.
1089610 - C May 2009
Page 2
Kohler Co.
2005/2/25 13
ROUGH-IN
B
A
DIMENSION ‘A’
872 ± 7.5mm
972 ± 7.5mm
872 ± 7.5mm
DIMENSION ‘B’
872 ± 7.5mm
972 ± 7.5mm
1161 ± 7.5mm
MAX. DOOR OPENING
480mm
500mm
480mm
1830mm
SIZE
900 x 900
1000 x 1000
1200 x 900
B
Top rail
A
46.5mm
Bottom rail
25mm
Elevation
1089610 - C May 2009
Plan view
Page 3
Kohler Co.
PARTS IDENTIFICATION
PARTS IDENTIFICATION
Stopper Screw
ST 3.9 X 12 mm
Right door stop
Left door stop
Top and bottom rail
Corner cover, top left
Corner cover top right
Door entry seal
Wall retainer
Clip screw
ST 4.2 X 9.5 mm
Top and bottom rail seal*
Infill glass
Wedge
Infill glass screw
ST 4.2 X 16 mm
Door Seal
Top roller sets*
Wall anchor
Wall retainer screw
ST 4.2 x 28mm
Door Handle*
Corner cover clip
Screw cover
Wall retainer seal
Corner cover clip
Return seal
Bottom roller sets*
Corner cover bottom right
Door panel assy right
Corner cover bottom left
1089610 - C May 2009
Door panel assy left.
Door edge cap
Magnetic seal
Page 4
Kohler Co.
DOOR INSTALLATION
1. Mark and drill wall retainer fixing holes
Measure and mark a line on the rim of the tray
using the following dimensions (all dimensions are
measured from the acrylic wall face):
SIZE
900 x 900
1000 x 1000
1200 x 900
DIMENSION ‘C’
862mm
967mm
1154mm
Pencil
DIMENSION ‘D’
862mm
967mm
862mm
Wall retainer
Level
right hand tray shown
Align the outside face of the wall retainer with the
mark on the rim of the tray.
Inside of
tray
Using a level, plumb the wall retainer, and mark
the three mounting holes with a pencil.
D
Use a 6mm drill bit to drill the holes.
C
Outside
of tray
Press fit the wall anchors into the holes.
Repeat this procedure for the other wall retainer.
Shower Tray
2. Install the wall retainers.
Install each wall retainer by aligning the holes in
the retainer with the wall anchors.
Wall retainer screw.
Secure the wall retainers wth 6 x ST 4.2 x 28 mm
screws provided.
ST 4.2 x 28 mm
B
1089610 - C May 2009
Page 5
Kohler Co.
3. Install the bottom rail.
Press fit the bottom rail into the wall retainer on the tray.
B
Note: Make sure there are seals in each end of the top
and bottom rails,and the end of the seal aligns with
the end of the rail.
Seal
Rail
4. Install the infill glass
Press fit the infill glass to the bottom rail.
B
Note: Make sure that the fixing holes in the
glass align with the holes in the bottom rail.
1089610 - C May 2009
Page 6
Kohler Co.
5. Install the top rail.
Press fit the top rail to the top end of both glass
infill panels.
Make sure that the glass infill panels align with
the end of the rails.
B
6. Adjust the top rail.
To make sure that the rails are correctly fitted to
the glass infill panels, use a tape measure to make
sure the total height of the assembled product is
1830 mm.
If higher, try pressing the top rail onto the glass
infill panels harder.
1830 mm
1830 mm
If lower, insert a wedge into the gap between the
glass infill panels and the top rail seal.
1830 mm
B
1089610 - C May 2009
Page 7
Kohler Co.
7. Fix the top and bottom rails to the glass infill panels.
Use a power drill on a low torque setting to drive the
countersunk screws into the top and bottom rails 8 places.
ST 4.2 x 16 mm
Take care not to over drive these screws.
ST 4.2 x 16 mm
8. Install the wall retainer seals
Press fit the wall retainer seals into the wall retainer.
Ensure the seals are fitted with the soft edge
in contact with the face of the glass, as show
in the illustration on the right hand side.
Soft edge of retainer seal
1089610 - C May 2009
Page 8
Kohler Co.
9. a) Referring to the diagram below, cut the return seals to the length leaving
a 3 - 5mm notch at the bottom so that the fexible flap overlaps
the curved still extrusion.
Return seal
b) Press fit the return seals onto
the vertical edges of both
return panels. The flexible flap
should point inside shower.
Flexible flap
Notch 3-5mm of rigid portion at bottom
of seals so that the flexible flap overlaps
the sill extrusion (right hand seal shown).
Return seal
(right hand)
Return panel
Sill extrusion
10. Install the door panels.
Identify the left door from the right door, referring to the handle location.
Note that the rollers on the top edge are height adjustable.
A) From the inside of the shower, hang the door panel on the top rail.
B) Press the button on the bottom rollers and fit the rollers into the bottom rail.
C) If there are gaps between the doors, raise or lower the doors by
adjusting the screws in the top rollers (clockwise to raise the door).
Once done there should be no gaps between the doors,
and the top edges must be level.
C
D) Press fit the door seals onto the vertical
edges of both doors.
A
D
B
1089610 - C May 2009
Page 9
Kohler Co.
11. Install the corner cover clips.
Move the bottom rail forward or backward to make
sure that the gap between the bottom rail and the
front edge of the tray is even.
ST 4.2 x 9.5mm
Make sure that the edges of the infill glass are vertical.
Drill a 2.5mm hole through the small holes at the top and
bottom ends of the retainers, and into the top
and bottom rail.
ST 4.2 x 9.5mm
Take care to not drill all the way through the retainers!
Fix the corner cover clips to the retainer. Make sure that
the pin on the back of the clip aligns with the large hole
at the top and bottom end of the retainer.
ST 4.2 x 9.5mm
12. Sealing the door.
CAUTION: Use only Sika Silaflex NG Silicone Sealant.
CAUTION: Apply silicone to the outside of the door
only. silicone applied to the inside of the door will
cause leakage and damage.
Thoroughly clean all surfaces. Remove all dust,
dirt or grease from the bottom rail, retainers
and shower tray.
For best results apply masking tape to within
5mm of the joints to be sealed.
Apply a bead of sealant around the outside of the
door where:
1. The bottom rail meets the tray.
2. The retainers meet the wall and the tray.
3. In and around the bottom corners where the
retainers meet the bottom rail, and behind the
corner cover caps.
NOTE: Allow silicone to cure for 24 hours before
using shower.
Apply silicone along the broken line
1089610 - C May 2009
Page 10
Kohler Co.
13. Fit door entry seals and corner covers.
Press fit the door entry seals into the channel
in the top side of the bottom rail, and the
underside of the top rail.
Press fit all four corner covers over the
corner cover clips.
1089610 - C May 2009
Page 11
Kohler Co.
CLEANING INSTRUCTIONS
Use non abrasive soap and water when ever possible.
In addition you may safely use:
• Mr Muscle Shower Clean (branded as Windex Shower
Clean in Australia).
• Jif Powerspray.
Avoid:
• harsh chemicals and disinfectants.
• abrasive cleaners.
• solvent based cleaners.
• acid or alkaline cleaners.
• products containing ammonia or peroxides.
Wipe out the unit after each use
to prevent build-up of scum.
Always read the label instructions on any cleaner
carefully before applying it to the surface.
Use a squeegee or dry towel to dry the glass after use.
Regularly wash down the extrusions with warm water
and mild soap solution.
Where greasy deposits are concerned, cleaning may
require a soft cloth dipped in white spirits.
Thoroughly rinse with water after cleaning to ensure
removal of all residues.
CALL US FOR HELP
NEW ZEALAND
KOHLER NZ Ltd.
Ph 0800 100 382
Fax 0800 664 488
www.englefield.co.nz
1089610 - C May 2009
AUSTRALIA
KOHLER Co.
Ph 1300 362 284
Fax 1300 652 284
www.englefield.com
Page 12
Kohler Co.