OPERATING HANDLE REPAIR AND REPLACEMENT

THE OPERATING HANDLE ON QUICK ACTING DOORS IS SUBJECT TO CONSIDERABLE WEAR AND TEAR.  USUALLY, PROBLEMS WITH AN OPERATING HANDLE STEM FROM WORN BUSHINGS, BUT THERE ARE OTHER SOURCES OF TROUBLE, TOO.  THE OPERATING HANDLE CAN BE REMOVED, REPAIRED AND REPLACED WITHOUT TAKING APART ANY OTHER DOOR COMPONENTS EXCEPT FOR THE LINKAGE THAT DIRECTLY ATTACHES TO THE HANDLE.

1. ROTATE THE OPERATING HANDLE INTO AN UNDOGGED POSITION.
   
   
2. WITH THE INSIDE HANDLE ENGAGED IN THE SPRING CLIP ASSEMBLY, REMOVE THE COTTER PIN AND CONROD COLLAR FROM THE TOGGLE LINK LEVER AND INSIDE HANDLE.
   
   
3. REMOVE THE JAM NUTS OR SELF-LOCKING NUT FROM THE OPERATING HANDLE SHAFT.
   
   
4. WITHDRAW THE OUTSIDE AND INSIDE HANDLES FROM THE SLEEVE.
   
   
5. REMOVE THE FLANGED BUSHINGS FROM THE SLEEVE.
   
   

1. REMOVE THE PACKING PLUNGER FROM THE OUTER HANDLE SPINDLE.  INSPECT THE PLUNGER AND IF ITS SCREWDRIVER SLOT OR THREADS ARE DAMAGED, REPLACE IT.
   
   
2. INSPECT THE INTERNAL THREAD ON THE SPINDLE AND IF IT IS DAMAGE, RE-TAP IT WITH A 5/16-24-3 UNF TAP.  IF THE BUSHINGS WILL BE REPLACED BY TRADITIONAL (NOT-SELF-LUBRICATING) BUSHINGS, CLEAN THE HOLE IN THE SPINDLE.
   
   
3. EXAMINE THE SPINDLE BEARING SURFACES ON BOTH THE INSIDE AND OUTSIDE HANDLE.  IF THE BEARING SURFACES HAVE DEEP SCRATCHES OR GROOVES, THE HANDLE SHOULD BE REPLACED.  IF THE SPINDLE THREADS ARE DAMAGED, REPAIR THEM WITH A 7/87-9-2 UNC DIE.
   
   
4. INSPECT THE HOLE IN THE INNER OPERATING HANDLE TO SEE THAT IT HOLDS THE SPINDLE SECURELY.  IF IT IS ENLARGED, THE HANDLES WILL BECOME MISALIGNED AND INTERFERE WITH THE OPERATION OF THE DOOR.  IF THERE IS EXCESSIVE WEAR, THE BEST SOLUTION IS TO REPLACE THE WORN HANDLE OR SPINDLE OR BOTH.  HOWEVER, IT IS POSSIBLE TO REPAIR A LOOSE HANDLE BY DRILLING A HOLE THROUGH THE HANDLE AND SPINDLE SHAFT AND, WHEN REASSEMBLING THE HANDLE, INSERTING A 1/8" ROLL PIN IN THE HOLE.
   
   
5. FOR STEEL DOORS, REMOVE CORROSION FROM THE INSIDE OF THE SLEEVE USING #320 GRIT ALUMINUM OXIDE CLOTH.  AFTER SANDING, CLEAN THE SLEEVE WITH A RAG AND SOLVENT.
   
   
6. IF YOU ARE INSTALLING SELF-LUBRICATED BUSHINGS, BLOCK THE HOLE IN THE HAND LEVER SHAFT WITH THE PLASTIC PLUG SUPPLIED IN THE PARTS KIT.
   
   
7. DAUB A THIN COATING OF SILICONE COMPOUND ON THE INSIDE OF THE FLANGED BEARINGS.  SIMILARLY, COAT THE INNER SURFACE THE THE HANDLE SLEEVE AND BOTH ENDS OF THE SLEEVE.  TRIAL FIT SELF-LUBRICATING BUSHINGS BEFORE COMPLETING REASSEMBLY; EVERYTHING SHOULD FIT TOGETHER UNDER HAND PRESSURE.
   
   
8. APPLY SILICONE COMPOUND TO THE SPINDLE OF THE OUTER OPERATING HANDLE AND INSERT IT IN THE FLANGED BUSHING, TAKING CARE NOT TO GET COMPOUND ON THE THREADS.
   
   
9. IF YOU ARE USING TRADITIONAL BUSHINGS, MOVE TO THE INSIDE OF THE DOOR AND WRAP 12" OF STRING PACKING AROUND THE OUTER HANDLE SPINDLE.  PUSH THE PACKING INTO THE SLEEVE WITH A SCREWDRIVER.
   
   
10. APPLY HAND PRESSURE TO THE OTHER FLANGED BUSHING AND GUIDE THE OPERATING HANDLE SHAFT THROUGH THAT BUSHING, TAKING CARE NOT TO GET LUBRICANT ON THE THREADS.
    
    
11. MOUNT THE INSIDE HANDLE AND CONNECT THE TOGGLE LINK.
    
    
12. THREAD THE CONROD COLLAR ONTO THE TOGGLE LINK LEVER STUD BUT DO NOT TIGHTEN IT.
    
    
13. INSTALL ONE JAM NUT OR SELF-LOCKING NUT AND TIGHTEN IT JUST ENOUGH TO ENGAGE 3 THREADS.
    
    
14. TIGHTEN THE CONROD COLLAR AND INSTALL ITS COTTER PIN.
    
    
15. INSERT A PACKING PLUNGER INTO THE HANDLE SPINDLE.
    
    
16. PERFORM A CHALK TEST.
    
    
17. FOR HANDLE ASSEMBLIES USING JAM NUTS, INSTALL THE SECOND JAM NUT.