FM08-301 140252 BW-100 Door Upgrade I N S T R U C T I O N S Part Description ASSY-TRACK & DOOR BW1 RETRO 1 ASSY-LH END PANEL BW100 1 ASSY-RH END PANEL BW100 1 HOUSING-PULLEY LEFT BW100 1 HOUSING-PULLEY RIGHT BW100 1 GUARD-PULLEY BW100 2 GUIDE-WEIGHT BW-100 2 STUD ASSY-PLATE PULL BW100 RH 1 STUD ASSY-PLATE PULL BW100 LH 1 WELD ASSY-WEIGHT LEFT BW RET 1 WELD ASSY-WEIGHT RIGHT BW RET 1 CHANNEL-DOOR BW100 SPACER 2 PULLEY-BW100 2 WELDNUT-MACHINED 2 1/2 " OPEN/CLOSED BUSHING 2 #8-18 X 7/16 PH IND XTRNL TRX (DALE 10 SCREW) Enclosure Top 1 #8 Self-Tapping Screw 6 Acorn Nut 2 #10 Nuts 4 Loctitie 1 Lock Washers 6 Cover - Label Clear 1 Label - Data Plate 1 Label - Left Drill Template 1 Label - Right Drill Template 1 Qty
A QUALIFIED TECHNICIAN MUST PERFORM THE UPGRADE. Remove unit and perform work in an area away from food prep area. TO AVOID INJURY OR PROPERTY DAMAGE, BEFORE STARTING THIS PROCEDURE, MOVE THE POWER SWITCH TO THE OFF POSITION. DISCONNECT THE MAIN CIRCUIT BREAKER AT THE CIRCUIT BREAKER BOX, OR UNPLUG THE SERVICE CORD AT THE RECEPTACLE. ALSO, TURN OFF THE MAIN GAS SUPPLY TO THE COOKER, OR POSSIBLE EXPLOSION COULD RESULT. MOVE UNIT BEFORE PERFORMING UPGRADE 1. Using a phillips head screwdriver or power drill, remove the screws securing the top cover. 2. Remove the screws from the side panel and remove. Repeat this for both sides of the unit. Figure b 3. With the side panels removed, locate the template. Place it on the lower corner of the control panel with the edge of the template flush with the edge of the mount as shown in. 4. Using a smaller bit, drill a pilot hole indicated on the template as shown in Figure b. Using a 1/2in. drill bit or a step up bit, finish drilling the hole to the appropriate size.. Repeat steps on opposite side of unit. Figure c 1
5. Using a 3/8 nut-driver or socket, remove the three (3) nuts closest to the door only. Set nuts aside for the next step. 6. Locate the counter-weight tracks and install using the nuts removed in the previous step. Repeat steps 6 &7 for the other side of the unit. 7. Locate the door assembly shown in the image above. 8. Flip the assembly front side down. 9. Locate the two (2) shims included in the kit. 10. Place shims on their appropriate sides of the assembly as show in. 2
11. Remove the old door assembly by removing the six (6) nuts from the back side with a 3/8in. wrench or socket. 12. Using the new door assembly, install in the same location as the old door assembly and tighten. Apply Loctite to the studs before installing the nuts. Three nuts per side need removed 13. Using a 3/16 in. drill bit, drill the TOP HOLE only as shown in. Repeat this step for the other side of the unit 14. Locate the pulley plate for the appropriate side. Insert the stud in the hole you drilled as shown in figure b. 15. Tighten the plate with a phillips head bit as shown in figure c. Figure b Figure c 3
16. Locate the pulley guard. Place center hole on the stud and tighten down with a phillips head bit or screwdriver as shown in. 17. Locate the pulley included in the kit. Place the cable in the groove of the pulley so the eyelet is going down the back side of the pulley. 18. Apply Loctite to the stud then start the nut by hand then tighten the pulley nut onto the center of the pulley with a pair of pliers. Repeat for opposite side. 19. After the pulley is secure, insert the cable in the hole that was drilled earlier in this process. 20. Locate the split-bushing included in the kit. 21. Insert the cable into the bushing and install the bushing (up) as shown below. Repeat these steps for the opposite side of the unit. 4
22. Locate the counterweights for the appropriate side. Place the counterweight onto the newly installed track as shown in. 23. As shown in Figure b, place the eyelet into the counterweight. 24. Apply Loctite then, tighten with a phillips head bit or screwdriver as shown in Figure c. Repeat these steps for the opposite side of the unit. Figure b Figure c 25. Place the new side panels in place. 26. As shown in the sequence below, using the self taping screws, secure the side panel by installing one (1) on the bottom, of the side panel (front side). Shown in Step 1. 27. Install another self taping screw on the top of the side panel located under the pulley. Step 2. 28. Install three (3) screws in the back of the panel to the unit. Step 3. Repeat steps for opposite side. Step 1 Step 2 Step 3 5
29. Locate the new top cover included in the kit. Place the cover on top of the unit. 30. Tighten the bolts as they were removed in the first operations. 31. Locate the pulley cover included in the kit. Using a phillips head bit or screwdriver, secure the cover to the unit. Repeat this step for the opposite side of the unit. 32. Locate the blank data plate and clear cover provided in the kit. Using a permanent marker, write the serial number onto the data plate in the area circled below. 33. After data plate is filled out, place onto unit circled to the figure to the left. Place the clear cover on top of the data plate to protect from damage. 6