Full Overlay Door Panel Preparation and Installation Instructions for 2175, 2115, CLR2160 Models www.U-LineService.com Phone (414) 354-0300 · FAX (414) 354-7905 Service & Parts Tech Lines Phone (800) 779-2547 · FAX (414) 354-5696 OnlineService@U-Line.com ©2006 U-Line Corporation 03/2006 Full Overlay Door Panel Door Panel Preparation A full overlay door panel completely covers the doorframe and handle to give a built-in appearance. See your U-Line dealer for the optional Full Overlay Door Panel Kit. 2175 Models: P/N U-OL2175B -- Black P/N U-OL2175W -- White 2115 & CLR2160 Models: P/N U-OL2115B -- Black P/N U-OL2115W --White Appropriate hardware, Modified Handle, Replacement Hinges and a copy of these instructions will be included in the kit. 1. Cut the overlay to the following dimensions (see Figure 1). Full Overlay Dimensions: 2. Create a relief (Figure 1) for pivot plate by cutting notch in top corner of overlay panel. Refer to Figure 2 for exact specifications. 15/32" ø 0.177" (#16 Drill) 11/16" Deep 3/8" 31/32" .125" 11/16" Ref BACK VIEW 1/4" Ref TOP VIEW 3/4" Min Ref 2175 Models: Width: 23-3/4" Height: 29-3/4" 2115 & CLR2160 Models: Width: 14-3/4" Height: 29-3/4" 3/8" SIDE VIEW 13/32" BOTTOM VIEW The door panel must not weigh more than 20 lbs. Figure 2 ø 5/16" x 1/4" Deep Chamfer 1/32" x 45° ULIN_0401_A 3/4" 31/32" Route notch in top corner of overlay panel as shown (see Top and Side Views). Top of notch is entire depth of panel, front to back. Width: 31/32" Depth: 1/8" 1/8" Relief Notch for Pivot Plate CAUTION Be careful not to drill too deep! Drilling holes too deep may destroy your door panel. Rear View of Wood Panel Height 3. Drill hole for upper door hinge (top of panel) (see Figure 2, Top View). 0.177" diameter (#16 drill) x 11/16" deep 4. Drill hole for lower door hinge (see Figure 2, Bottom View). Width 5/16" diameter x 1/4" deep ULIN_0400_A Figure 1 CAUTION 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. IMPORTANT Rear View of wood panel for right-hand hinge shown. Use mirror image for left-hand hinges. www.U-LineService.com 2 03/2006 Installation Instructions Removing Existing Door 1. Remove the door shelves by first pulling shelves up at a 45° angle, then straight out. 2. Remove top hinge screw pin (Phillips screwdriver). Remove the door by tilting forward and lifting off the bottom hinge pin. 3. 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 3). This may take some force. Side of Wood Panel 5/16" Bottom 3/8" Both Sides Back of Wood Panel Tape Removed Door Panel Bottom of Wood Panel Figure 5 Old Handle 2-5/8" ± 1/4" New Handle Drill ø 5/32" x 3/8" Deep 7 Places Model 2175 6 places Model 2115 and CLR2160 For use with #10 x 5/8" Wood Screw and Nylon Spacer 15-9/16" ± 1/4" Figure 3 Figure 4 ULIN_0403_A 4. Remove the two screws located on both sides of the handle. 5. Remove the handle and discard. (This handle will be replaced with the Overlay Handle included in the Full Overlay Door Panel Kit.) 6. Slide the existing door panel out of the doorframe. Attaching the Full Overlay Panel 1. Place and tape the existing door panel on the back of the overlay panel (see Figure 5) and drill holes through both panels according to Figure 6. Remove tape adjoining the panels and enlarge the six holes in the overlay panel using a 0.201" (#7) drill. 2. If a user-supplied cabinet handle will be used, attach its hardware to the overlay panel at this time. 1" 11-7/8±1/32 For use on Model 2175 Only 1" 28-7/8" ± 1/4" ULIN_0402_A Figure 6 3. Attach the door panel to the overlay panel using #10 x 5/8" wood screws and nylon spacers. The nylon spacers fit between the overlay panel and the door panel as shown in Figure 7. The spacers allow the original door panel to slide back into the 1/4"-thick door reveal (channel). 03/2006 3 www.U-LineService.com Typical Wood Panel Door Panel Wood Panel Top Hinge Plate (5/8" Longer than Existing Top Hinge Plate) Pivot Post #10 x 5/8" Round Head Screw Seven Required Plastic Spacer Seven Required #8-32 x 1/2" Flat Head Screw Three Places Figure 7 ULIN_0404_A Top Pivot Plate 4. Remove the existing bottom pivot plate and replace with the Full Overlay pivot plate (see Figure 8). Figure 9 Door Panel ULIN_0405 Existing Door Existing Bottom Pivot Plate (Remove and Discard) Wood Panel Bottom Pivot Plate (5/8" Longer Than Existing Bottom Pivot Plate, Flush Side Facing Out) #8-32 x 3/8" SEMS Hex Screw Two Places 3. Install the pivot post into the new Replacement Bottom Hinge (using the Phillips screwdriver) and install the hinge onto the unit. 4. Replace the door closure assembly onto the bottom pivot post (see Figure 10). Be sure that bosses on closers align with holes in hinge and hinge plate. Figure 8 IMPORTANT Door panel and overlay panel must be aligned properly or the door will not operate correctly. Assembling the Door 1. Install the assembled panel by sliding the original door panel back into the doorframe. 2. Replace the Overlay Handle and secure with the two screws removed in Step 4 under Removing Existing Door. 3. Starting at the corners and working toward the center, push the door gasket back into place. Installing the Door 1. Remove the existing hinges from the unit, saving the door closure assembly. 2. Install the new Replacement Top Hinge onto the unit (see Figure 9). Door Closure Top Door Closure Bottom Boss Existing Door Boss #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 Figure 10 IMPORTANT Pivot posts must be cleaned. Closers must also be clean and greased to ensure proper operation. 5. Place the modified door onto the pivot post. 6. Position door and install the pivot post into the top hinge (using the Phillips screwdriver). 7. Adjust door as needed for proper closure. 8. Check to see that light goes off when the door closes. 9. Reinstall the door shelves by lining up the bosses and first pushing straight in, then down at a 45° angle. www.U-LineService.com 4 03/2006 Checking Door Alignment The unit's door is aligned at the factory before shipment. However, its alignment could have been disturbed during shipment or during door panel installation. Adjusting Door Alignment 1. Remove top hinge screw pin (Phillips screwdriver, see Figure 12). Remove door by tilting forward and lifting off bottom hinge pin. 2. With door upside-down, loosen but do not remove the two screws on the door's bottom hinge plate. Figure 12 IMPORTANT Properly aligned, the door should be 1/8" below the top of the unit's cabinet, NOT flush with the top (see Figure 11). 1/8" Figure 11 1. Compare the top edge of the door to the top edge of the cabinet. 2. If the door edge is 1/8" below and parallel to the top of the cabinet, the door is aligned. If it is not, note whether the side opposite the hinge needs to be moved UP or DOWN, and use the following procedure. Note: If door is adjusted correctly, but panel is not square with the adjacent cabinets, slight adjustments can be made by drilling the holes in the vinyl coated steel panel slightly oversized. See Figure 6 on Page 3. Slotted Mounting Holes Notch (must face toward center of door) Raise Outside Door Edge Lower Outside Door Edge Figure 13 3. See Figure 13. If the top far edge of the door needs to move UP, move the hinge plate toward the outside of the door and retighten screws. If the top far edge of the door needs to move DOWN, move the hinge plate toward the inside of the door and retighten screws. 4. Mount the door to recheck alignment and repeat Steps 2 and 3 if further adjustment is necessary. 5. When top edge of door is parallel to top edge of cabinet, remove the door and ensure the two screws are secure. 6. Remove the door closers from the bottom hinge, clean thoroughly and lubricate the mating surfaces with petroleum jelly. 7. Reinstall the closers, lining up the bosses with holes in hinge and hinge plate (see Figure 14). 8. Mount the door and install top hinge pivot pin. Door Closer Inserts Boss Figure 14 03/2006 5 www.U-LineService.com Who to Call Service Information If the need for service arises, contact the dealer from whom the unit was purchased. State the Model Number and Serial Number and explain the problem. The Model and Serial Number plate is located inside unit at upper right hand corner. If you need to locate a service company, you can go online at www.U-LineService.com and search for a service company by zip code. For more than four decades, U-Line has distinguished itself as the leader in built-in undercounter ice making, refrigeration and wine storage appliances. U-Line Corporation, located in Milwaukee, WI, is a family operated manufacturer of built-in undercounter icemakers, Combo® icemaker/refrigerators, Wine Captain® wine storage units, refrigerators, refrigerated drawers and refrigerator/freezers. ©2006 U-Line Corporation Publication No. 30137 03/2006 Rev. A ...