U-Line Overlay Panel Conversion User Manual

Full Overlay Door Panel
To Convert 2075, 2015 and CLR2060
Panels for Use on the New
2175, 2115, CLR2160 Models

Service & Parts Tech Lines Phone [phone] • FAX [phone]

Publication No. 30163

www.U-LineService.com

Phone [phone] • FAX [phone]

[e-mail]

©2006 U-Line Corporation

04/2006

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
force.

Figure 1

). This may take some

1"

Figure 4

3/4"

1/8"

ULIN_0363_A

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.

Old Handle

New Handle

Figure 1 Figure 2

ULIN_0403_A

4. Remove the two screws located on both sides of the
handle.

5. Remove the door panel from the door.

6. Discard the old door.

Preparing the old panel for the new door:

1. Remove the existing metal panel backer.

2. Remove the existing L-shaped angle bracket in the top
corner.

3. Modify the notch in the top corner of the door. The
width needs to be changed to 1" (see

Figure 3

).

Back of

Wood
Panel

Side of

Wood Panel

Figure 5

Tap e

7/16"

Bottom

Drill ø 5/32" x 3/8" Deep

6 places Model 2115 and CLR2160

7 Places Model 2175

For use with #10 x 5/8"

Wood Screw and Nylon Spacer

Removed

Door Panel

3/8"

Both Sides

3"

Bottom of

Wood Panel

16"

Remove this
Material

±

28-7/8"

1/4"

Old New

Figure 3

4. Create an identical notch in the bottom corner of the
door, directly under this notch - 1" wide by 1/8" high by
3/4" deep (see

Figure 4

).

ULIN_0358_A

1.5"

Figure 6

12.25

"

For use on

Model 2175 Only

1.5"

ULIN_0365 _A

www.U-LineService.com 2 04/2006

3. Attach the door panel to the overlay panel using #10 x

A

5/8" wood screws and nylon spacers. The nylon spacers
fit between the overlay panel and the door panel as
shown in
door panel to slide back into the

Figure 7

. The spacers

allow the original

1/4"-thick door

reveal (channel).

Drill here

Figure 7

Typical

Wood Panel

Plastic Spacer

Seven Required

Door Panel

#10x 5/8"

Round Head Screw

Seven Required

ULIN_0404_A

4. Remove the existing bottom pivot plate and replace
with the Full Overlay pivot plate (see

Existing

Door

Existing Bottom Pivot Plate

(Remove and Discard)

Figure 8

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

Figure 8

Figure 9

ULIN_0359_A

2. Using a 5/16" bit, follow the same procedure with the
lower pivot pin/closer clearance hole (see

Figure 10

Figure 10

Drill here

ULIN_0360_

).

3. Insert the hinge hole plug into the opposite side of the
door hinge plate (see

Figure 11

and

Figure 12

).

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.

Pivot Post Clearance:

1. Using the upper pivot plate as a guide, use a #16 drill
and drill into the wood panel approximately 3/4"
through the pivot pin hole to provide clearance for the
pin in the door panel

(see

Figure 9).

Figure 11

Figure 12

ULIN_0361_A

ULIN_0362_A

04/2006 3 www.U-LineService.com

Installing the Door

5. Place the modified door onto the pivot post.

1. If the cabinet already used an overlay door, there is no
need to change the hinges.

2. Install the new Replacement Top Hinge onto the unit
(see

Figure 13

Wood Panel Top Hinge Plate

(5/8" Longer than Existing Top Hinge Plate)

Figure 13

).

Pivot Post

Door Panel

#8-32x 1/2"

Flat Head Screw

Three Places

Top Pivot Plate

ULIN_0405

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 14

). Be sure that bosses on

closers align with holes in hinge and hinge plate.

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.

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.

IMPORTANT

Properly aligned, the door should be 1/8" below the top of
the unit’s cabinet, NOT flush with the top (see

1/8"

Figure 15

1. Compare the top edge of the door to the top edge of
the cabinet.

Figure 15

).

Existing

Door

Door Closure Top

Door Closure Bottom

Boss

Pivot Post

Boss

#8-32 x 1/2" Flat Head Screw

Three Places

Wood Panel Bottom Hinge Plate

(5/8" Longer than Existing Bottom Hinge Plate)

Figure 14

IMPORTANT

Pivot posts must be cleaned. Closers must also be clean
and greased to ensure proper operation.

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 2.

www.U-LineService.com 4 04/2006

Adjusting Door Alignment

1. Remove top hinge screw
pin (Phillips screwdriver,
see Figure 16). 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.

Slotted

Mounting

Holes

Figure 16

Notch
(must face toward
center of door)

3. See

Figure 17

. 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 18

8. Mount the door and install
top hinge pivot pin.

).

Door

Closer

Inserts

Raise

Outside

Door Edge

Figure 17

Lower

Outside

Door Edge

Boss

Figure 18

04/2006 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.