Serene HB80 - Door Frame Cracking

Overview

It has been identified that the HB80 plastic door fame can develop a crack next to the top hinge pin. This can
start as a hairline crack and has the potential to become a full breakage if the hinge bush is raised.

The purpose of this service bulletin is to cover how to inspect the door frame for a crack, and if a crack is
found how to replace the door.

Inspection

If inspection is to be done to a new cabinet, still packed, this can be done with the cabinet still in the carton.

1. Remove the carton straps, open the carton top, and remove the polystyrene top cap.
2. Inspect the door frame area around the top hinge, looking for a crack or raised hinge bush. The bush should fit snugly and flush in the hinge hole.
3. Reject the door if a crack is detected or the bush does not sit flush with the hinge hole.
4. If no crack is found, and the hinge bush sits flush, the cabinet can be repacked.

Replacing the Door

Before fitting a new door it should first be inspected for any damage. If a crack is detected, the hinge bush is
raised or the door frame is deformed in any way, the door should be replaced.

1. Inspect the door frame around the top hinge hole. If the hinge bush is protruding remove the bush and check that the holes in the door frame are concentric. The bush should fit flush in the hinge hole.
2. Reject the door if a crack is detected or the bush does not sit flush in the hinge hole.
3. If no crack is found, and the hinge bush sits flush, the new door can be fitted.
4. Remove the plastic top hinge cap and remove the hinge bracket by using a screwdriver or 8mm spanner or socket.
5. Lift the door off the bottom hinge and place to one side.

6. Remove the existing door gasket by carefully pulling it out of the door frame and refit the gasket to the
new replacement door.
7. Remove the existing door lock by first pulling out the lock tongue from underneath the door, and then
turn the lock so the lever pulls out of the slot in the door frame.
8. Refit the lock and lock tongue to the new replacement door.

Fitting the New Door

1. Prop the front of the cabinet so it is leaning back slightly.
2. Place the door on the cabinet and give the hexagon torsion bar 1/4 turn clockwise, as you look at it.
3. Align the hexagon torsion bar into the bottom hinge hole with the correct torsion applied.
4. Align the door and refit the top hinge and plastic hinge cover.
5. Remove the prop from under the cabinet and check the door opens and self closes.
6. Repack the cabinet into the original carton and re-strap.