User manual ULINE ECHELON 2075R - SUPPLEMENTARY GUIDE

Full Overlay Door Panel Installation Instructions for Models 2075, 2015 and CLR 2060 U-Line Corporation P Box 245040 · Milwaukee, WI 53224-9540 .O. Phone 414.354.0300 · FAX 414.354.7905 Printed in U.S.A. P/N 30-10011 Part Number 12041 42120 42121 42122 11901-2* 12020* 12021* 12029* 31672 31673 42161-ZP 42096 42101 Description Insert 8mm Plug Spacer Nylon 3/8 OD x .19 ID Screw #10 x 5/8 Round Head Screw #6 x 1/2 Large Flat Head Pivot Plate Wood Wood Panel Bottom Hinge Wood Panel Top Hinge Top Pivot Bracket Door Closer - Male Door Closer - Female Screw #8-32 x 3/8 Hex Sems Pivot Post Screw #8-32 x 1/2 Flat Head Quantity 2 8 8 2 1 1 1 1 1 1 2 2 6 1 1 1 1 80-17006-01** 2015 BLK Modified Top Handle Assy. 80-17006-02** 2015 WHT Modified Top Handle Assy. 80-17006-03** 2075 BLK Modified Top Handle Assy. 80-17006-04** 2075 WHT Modified Top Handle Assy. *Specify Black or White **Only one handle is included with this kit 1. REMOVE EXISTING DOOR FROM THE CABINET a. Remove top hinge screw pin (7/64" hex key). Remove the door by tilting forward and lifting off the bottom hinge pin. b. Pull door gasket out of the groove (top edge of door only). Start in the middle and pull outward, moving toward the edge (see Figure 1). This may take some force. c. Remove the three screws located Figure 1 on the back of the handle (see Figure 2). d. Remove the top handle and discard. (This handle will be replaced with the modified handle included in the full overlay kit.) e. Remove the two screws located on both sides of the lower handle. Remove the handle. f. Attach the modified handle to the lower handle using the three screws removed in Step Figure 2 1 C. Set aside. g. Slide the existing door panel out of the door frame. NEW HANDLE OLD HANDLE 2. PREPARE THE NEW OVERLAY PANEL Refer to the Full Overlay Panel Preparation instruction sheet. The full overlay door panel must not weigh more than 20 lbs. The thickness of the door panel must be 3/4". 3. ATTACHING THE FULL OVERLAY PANEL a. Tap nylon inserts into the top holes drilled in the wood panel. Use two #6 screws (P/N 42122) to attach top pivot bracket (P/N 12029) to the wood door panel (see Figure 3). TOP PIVOT PLATE TYPICAL WOOD PANEL #6 X 5/8" FLAT HEAD SCREW TWO REQUIRED 8MM PLUG INSERT TWO REQUIRED Figure 3 b. If required, attach optional cabinet handle hardware to the wood door panel at this time. c. Place and tape the existing door panel on the back of the wood panel (see Figure 4) and drill holes through both panels according to the diagram (see Figure 5). Remove tape from the door panel, and enlarge the seven holes in the front panel using a 0.201'' (#7) drill. BACK OF WOOD PANEL TAPE DOOR PANEL SIDE OF WOOD PANEL BOTTOM OF WOOD PANEL 5/16" BOTTOM 3/8" BOTH SIDES Figure 4 DRILL 5/32" x 3/8" DEEP 7 PLACES - MODEL 2075 6 PLACES - MODEL 2015 and CLR 2060 FOR USE WITH #10 x 5/8" WOOD SCREW AND NYLON SPACER 27" ± 1/4" 14-5/16" ± 1/4" 1" ± 1/8" 1" ± 1/32" 11-7/8" FOR USE ON MODEL 2075 ONLY. 1" ± 1/32" Figure 5 For Models 2015 and CLR 2060, omit the center hole. d. Attach the door panel to the wood panel using #10 x 5/8'' (P/N 42121) wood screws and nylon spacers (P/N 42120). The nylon spacers fit between the wood panel and the door panel as shown (see Figure 6). TOP PIVOT PLATE TYPICAL WOOD PANEL #10 X 5/8" ROUND HEAD SCREW SEVEN REQUIRED DOOR PANEL PLASTIC SPACER SEVEN REQUIRED Figure 6 Door panel and wood panel must be aligned properly or door will not operate correctly. e. Remove the existing bottom pivot plate and replace with the overlay panel pivot plate (P/N11901-2) (see Figure 7). EXISTING DOOR EXISTING BOTTOM PIVOT PLATE (REMOVE AND DISCARD) WOOD PANEL BOTTOM PIVOT PLATE (5/8 INCH LONGER THAN EXISTING BOTTOM PIVOT PLATE, FLUSH SIDE FACING OUT) #8-32 X 3/8" SEMS HEX SCREW TWO PLACES Figure 7 4. ASSEMBLING THE DOOR AND WOOD PANEL a. Install the overlay panel by sliding the door panel back into the door frame. b. Replace the two-piece modified handle assembly and secure with the two screws removed in Step 1 E. c. Starting at the corners and working toward the center, push the door gasket back into place. 5. INSTALLING THE DOOR a. Remove the existing hinges from the cabinet, saving the door closure assembly. b. Install the top (P/N 12021) hinge to the cabinet (see Figure 8). PIVOT POST WOOD PANEL TOP HINGE PLATE (5/8" LONGER THAN EXISTING TOP HINGE PLATE) #8-32 X 1/2" FLAT HEAD SCREW THREE PLACES TOP PIVOT PLATE DOOR PANEL Figure 8 c. Install the pivot post (P/N 42096) into the bottom hinge (using the 7/64'' hex key) and install the hinge onto the cabinet. d. Replace the door closure assembly onto the bottom pivot post (see Figure 9). Be sure that bosses on closures align with holes in hinge and hinge plate. EXISTING DOOR DOOR CLOSURE TOP DOOR CLOSURE BOTTOM #8-32 X 1/2" FLAT HEAD SCREW THREE PLACES WOOD PANEL BOTTOM HINGE PLATE (5/8" LONGER THAN EXISTING BOTTOM HINGE PLATE) PIVOT POST BOSS Figure 9 Pivot posts must be cleaned. Closers must also be clean and greased to ensure proper operation. e. Place the modified door onto the pivot post. f. Position door and install the pivot post (P/N 42096) into the top hinge (using the 7/64'' hex key). g. Adjust door as needed for proper closure. h. Check to see that light switch actuator bracket is contacting the light switch properly. Full Overlay Panel Preparation for EchelonTM Models 2075, 2015 and CLR 2060 The full overlay door panel must not weigh more than 20 lbs. The thickness of the door panel must be 3/4". 1. Cut door panel to proper size (Figure 1). Be sure to note which model the door will be used on. PIVOT PLATE RELIEF SEE FIGURE 2 29-7/8" MODEL 2075: 23-3/4" MODEL 2015 and CLR 2060: 14-3/4" Figure 1 Rear View of Wood Panel For Right Hand Hinge Shown. Use Mirror Image For Left Hand Hinges. 2. Create a relief (Figure 2) for pivot plate by cutting notch in top corner and coinciding back corner of panel. Refer to the following figures for exact specifications. 3/4" 13/16" 1/8" 1/8" U-LINE034 Figure 2 Relief Notch for Pivot Plate Printed in U.S.A. P/N 30-10014 (Rev. 8/2004) 13/32" 0.177" Dia. (#16 DRILL) X 11/16" DEEP 3/8" 13/32" 3/8" 13/16" DOOR BOTTOM: 5/16" Dia. X 1/4" DEEP CHAMFER 1/32" X 45° Figure 3A Top View of Door 13/32" 1/8" 5/16" Dia. X 1/2" DEEP Figure 3C Bottom View of Door 1/8" 13/16" 1-17/32" 1/8" R1/32" 7/16" 13/16" R1/8" 3/4" Figure 3B Back View of Door Figure 3D Side View of Door 2A. Route notch in top corner of panel as shown (Figures 3A and 3D). Notch is entire depth of panel, front to back. Width: 13/16" Depth: 1/8" 4. Drill hole for upper door hinge (top of panel) (Figure 3A). 0.177" diameter (#16 drill) x 11/16" deep 5. 2B. Route notch in back side of top corner of panel (Figures 3B and 3D). Width: 13/16" Depth: 1/8" Height: 1-17/32" from top edge of panel (less 1/8" for depth of notch on top of panel) Radius of corner notch: 1/8" (Figure 3B) 3. Drill holes for pivot plate mounts (Figure 3B). 5/16" diameter x 1/2" deep, from the routed surface Drill hole for lower door hinge (Figure 3C). 5/16" diameter x 1/4" deep NOTE It is important to ensure that all drilled holes are drilled to the correct depth in order to avoid splits in the wood when hardware is installed. U-Line Corporation P Box 245040 · Milwaukee, WI 53224-9540 .O. Phone 414.354.0300 · FAX 414.354.7905 www.u-line.com