MARVEL FULL OVERLAY PANEL FOR SOLID DOORS Full Overlay Panel for Solid Doors Installation Instructions Wine Cellars 3SWC 3SWCE 30WC 30WCM Beverage Centers 3SBAR 3SBARE 3BAR 3BARM Refrigerators 30AR Ice Machines 25iM 30iMT FULL OVERLAY PANEL INSTALLATION INSTRUCTIONS STEP 1: WOOD SCREWS REQUIRED STEP 2: ASSEMBLING DOOR HINGE BUSHING BRACKETS 1. A #8 pan head wood screw should be used to properly secure the overlay panel. A total of 10 screws will be needed for a 3 1/2 inch toe kick or 8 screws for a 4 inch toe kick. 2. Use only pan head screws. 3. DO NOT select a screw that is longer than the wood thickness at the screw locations. 4. Use recommended pilot holes for the frame material (see Table A below). Table A: Pilot Hole Drill Sizes For Wood Screw Work Material Wood Screw Size 8 Hardwood 3/32 Softwood 5/64 Disregard if hinges are already attached. 1. Attach the top and bottom door hinge bushing brackets to the door with the 1/4-20 machine screws and a 5/32 inch Allen head driver as shown in Figure 1. 2. Press in the shoulder bushings to the top and bottom door hinge bushing brackets. Make certain that the shoulder is to the outside of the door as shown in Figure 1. 3. Test fit the door to the unit to make certain door will hang correctly. The door is hung correctly when the top of the door is parallel to the top of the unit. Adjustments can be made by loosening the door hinge bushing brackets machine screws and moving the door up or down or side to side. 4. Tighten all four machine screws after adjustments have been made. 5. Remove the door from the unit by removing the unit’s top hinge set screw and angling the door off of the bottom hinge pin. This surface parallel to the unit (right hand swing door shown). Shoulder Bushing Door Hinge 1/4-20 Machine Screws Door Hinge Screw Holes Door Front Surface Figure 1: Typical Top and Bottom Door Hinge Assembly 1 FULL OVERLAY PANEL INSTALLATION INSTRUCTIONS STEP 3: SELECTING AND PREPARING THE OVERLAY PANEL Optional for a 4 inch Toe Kick (To Match Existing Cabinetry Toe Kick Height) For a 3.5 inch Toe Kick (Covers the Entire Door Extrusion) 0.63 Min. 0.75 Max. 0.25 dia x 3/8 Deep Hinge Screw Clearance Hole. Locate and drill using drill hinge hole after the door has been aligned to the unit and when the wood is positioned on the door. 14.75 0.63 Min. 0.75 Max. Mounting Surface (Non-Face) Side 8.94 0.25 dia x 3/8 Deep Hinge Screw Clearance Hole. Locate and drill using drill hinge hole after the door has been aligned to the unit and when the wood is positioned on the door. 14.75 5.81 0.73 Top & Bottom Mounting Surface (Non-Face) Side 8.94 5.81 0.73 5.73 5.73 Top Surface 15.16 0.81 Both Sides 15.16 24.59 0.81 Both Sides 29.81 30.31 Pre-Drilled Pilot Holes 10 Places See Step 1, for Drill Size Pre-Drilled Pilot Holes 10 Places See Step 1, for Drill Size Mounting Surface (Non-Face) Side 24.59 Mounting Surface (Non-Face) Side 0.25 dia x 3/8 Deep Hinge Screw Clearance Hole. Locate and drill using drill hinge hole after the door has been aligned to the unit and when the wood is positioned on the door. Mounting Surface (Non-Face) Side Mounting Surface (Non-Face) Side 0.25 dia x 3/8 Deep Hinge Screw Clearance Hole. Locate and drill using drill hinge hole after the door has been aligned to the unit and when the wood is positioned on the door. 2 FULL OVERLAY PANEL INSTALLATION INSTRUCTIONS STEP 4: DETERMINING DOOR SWING The door you received is for a right hand swing unit. If the unit is to be changed to a left hand swing door, pre-drilled striker plate holes are in place on the backside of the door on both ends. No additional drilling is necessary to mount the striker plate when you reverse the door swing. Just unscrew the striker plate from the location it is mounted to for right hand swing and then mount the striker plate at the end opposite of its previous location with the existing screws. If your door has an inner door liner with formed in shelves, it will need to be turned around for use in the left hand swing. Using a small, flat blade screwdriver, pop the plastic screw covers up to access the Phillips screws that secure the formed door liner to the door. Using a Phillips screwdriver, remove the Phillips screws that secure the formed door liner to the door. Rotate the formed door liner 180 degrees, line up the mounting holes in the door liner with the mounting holes on the door. Use the existing fasteners and plastic screw caps to secure the formed door liner to the door. Your door swing conversion is complete. Holes for screws to mount striker plate are already pre-drilled at factory. New Door Bottom for Left Hand Swing Door Striker Plate for Plunger Light Switch Figure 4: Striker Plate Hole Location 3 Remove the nameplate for the glass door by gently pulling it up and away from the glass surface. Relocate the nameplate using the supplied nameplate locator (part number: 41006022). 2.38 Figure 5: Nameplate Locator FULL OVERLAY PANEL INSTALLATION INSTRUCTIONS STEP 5: ATTACHING THE OVERLAY PANEL TO THE DOOR (WITHOUT THE LOCK AND KEY FEATURE) CAUTION Door can become disengaged if washers are not installed. 2 Nylon Hardware Components at Top Hinge 0.625 OD x 0.218 ID Washer Shoulder Bushing Door Hinge Bushing Bracket Overlay Panel Top Hinge Corner CAUTION Door can become disengaged if washers are not installed. Refrigerator Door 1. If the door is attached to the unit, remove it by unscrewing the top Allen head set screw at the top hinge. Remove the door by angling the door off of the bottom hinge pin. 2. Peel back door gasket to expose the screw holes. 3. Set the overlay panel flush to the front of the door in the desired location. Clamp overlay panel to the door if necessary. 4. Insert the wood screws through the back of the door into the pilot holes in the overlay panel and tighten. 5. Reinstall door gasket by pressing into door channel. Make certain the corners are inserted fully. 6. Install the door to the unit. Use the supplied plastic washers as shown in Figure 6. 7. Realigning the door may be necessary. Any final door adjustments can be made using a 5/32 inch Allen head driver to adjust the door’s hinge bushing brackets (see Figure 7). 8. Attach the door light striker plate as shown using the Hex or Phillips head screws provided. Make certain the light is able to turn on and off when the door is opened and closed. 9. Attach the door to the unit by reversing step number 1 above. Overlay Panel Magnetic Door Gasket 0.38 dia Clearance Door Hinge Bushing Bracket Holes for Screws 8 Holes Shoulder Bushing CAUTION Door may not swing properly if all nylon components are not installed as shown. 0.75 OD x 0.443 ID Washer 0.75 OD x 0.257 ID Washer 3 Nylon Hardware Components at Bottom Hinge Rear of Door Bottom Hinge Corner Figure 6 5/32 inch Allen Head Screws for Door Hinge Bushing Bracket Adjustment Door Hinge Bushing Bracket Adjustment Screws Attached Overlay Panel Light Door Striker Bottom of Door Figure 7 4 www.lifeluxurymarvel.com Marvel Industries P.O. Box 997 Richmond, IN 47375-0997 800.428.6644 An AGA Company 41008118 Rev C 10.30.07 All specifications and product designs subject to change without notice. Such revisions do not entitle the buyer to corresponding changes, improvements, additions, replacements or compensation for previously purchased products.