ZEPHYR PRB24C01AS Solid Panel Ready Door Kit Instruction Manual

PRPNLC24AKIT Solid Panel Ready
Door Kit

The PRPNLC24AKIT kit allows you to replace your existing glass panel ready door with a solid panel ready door. It will also replace the existing hinges and kickplate. The kit is compatible with the following coolers: PRB24C01AS- OD, PRKB24C01AG, and PRKB24C01AS-OD.

List of Materials

| Solid wood panel ready door
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| Self-tapping screws (ST430)
| Door handle screws (M440)
| Flat washers (Φ4.3Φ80.5, M4)
| Upper hinges, black
| Upper hinge screws (M412)
| Lower hinges, black
| Lower hinge screws (M512)
| Left hinge connecting plates, black
| Hinge connecting plate screws (M412)
| Top screw, black
| Door axis plate, black
| Door axis plate screws (M58)
| Kick  plate, black
| Kick plate self-tapping screws (ST48)
| Flat washers (Φ10.5Φ171.5)
Flat washers (Φ8.5Φ17*1.5)

Product Specifications

Wood Overlay Panel Dimensions

Installing the Solid Panel Ready Door

Refer to the installation manual for your product and read all warnings prior to installing the solid panel ready door. To install the solid panel ready door, please follow the instructions below. If you wish to reverse the door swing for your cooler, referto the installation manual of your specific model.

1. From the cooler, remove the 2 screws (M5*8) from the lower door axis. Then, remove the axis plate (1) and door (2).

2. Remove the top right hinge (3) by 3 screws (M4*12).

3. Lean or place the cooler on its back.
   Remove the 3 bottom screws (ST4*8) from the kick plate.

4. Remove the bottom bracket by 4 screws.

5. Remove the connection terminal by 1 screw from the magnet switch wire clip. Then, remove the kick plate (5) by 2 screws (ST4*8).

6. Remove the lower left hinge (6) and lower right hinge (7) by 3 screws (M5*12) each.

7. Install the new black lower left hinge (8) and black lower right hinge (9) by 3 screws (M5*12) each.

8. Refer to steps 5, 4, and 3 to reconnect the connection terminal by 1 screw from the magnet switch wire clip, install the bottom bracket by (4) screws, and install the new black kick plate (10) by 5 screws (ST4*8).

9. Install the new black upper left hinge (11) by 3 screws (M4*12).

10.  Insert the solid panel ready door (12) into the upper right hinge. Secure the door by installing (2) washers (Ø10.5Ø171.5) (13) and (Ø8.5Ø171.5) (14) into the lower hinge connecting plate and new black axis plate (15) to the lower door axis with 2 screws (M5*8).

11. Install the black top screw (16) on top of the hinge.

Installing the Wood Overlay Panel

To install the solid wood overlay panel onto the door, please follow the instructions below. Refer to the dimensions on page 2, to ensure proper measurements prior to installation.

1. Open the door.
2. Temporarily remove the door gasket to see the 10 holes for the overlay panel. There are 2 holes on the top and bottom sides of the door with either 3 or 5 holes on the left and right side depending on where the handle is located. The handle side will have 5 holes.
3. Open the hardware package containing (10) ST4*30 self-tapping screws for the overlay panel.
4. Clamp the overlay panel with the door firmly with bar clamps and screw the self-tapping screws into the overlay panel. Perform this step per screw until the overlay panel is completely secured.
5. Reattach the door gasket and close the door.

Installing the Optional Door Handles

If optional contemporary or pro handles are desired, refer below for the part numbers. You may install your own door handle onto the wood overlay panel. Take care to measure and drill the handle screw holes accurately and source the appropriate screws (not included) unless using Zephyr accessory handles.

1. Confirm if the wood overlay panel has already been installed onto the unit. If not, refer to installing the wooden overlay panel on page 5, to mount the overlay panel onto the unit.
2. Push aside the door gasket. Under the gasket you will see two designated holes for door handle installation. Mark door handle hole locations on the wood overlay panel.
3. Remove wood overlay panel from door. Using 3/16” drill bit, create holes for handle screws.
4. Re-install wood overlay panel on the door.
5. Install the handle tightly as shown with (2) M4*40 screws and (2) M4 flat washers.

NOTE: If using a custom handle, install the handle in the position of your choosing with countersunk screw holes prior to installing the wood overlay panel to the door.

CAUTION
Before powering on the cooler, make sure it has been in the upright position for as long as it was in the horizontal position
plus 1 hour. This will allow the coolant and oils to settle and prevent damage to the sealed system.

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