DKE RCM Door User Manual - ETS

Double Knife Edge (DKE)
Recessed Channel Mechanism
(RCM) Door
Maintenance Guide
ETS-Lindgren Inc. reserves the right to make changes to any product described
herein in order to improve function, design, or for any other reason. Nothing
contained herein shall constitute ETS-Lindgren Inc. assuming any liability
whatsoever arising out of the application or use of any product or circuit
described herein. ETS-Lindgren Inc. does not convey any license under its
patent rights or the rights of others.
© Copyright 1994–2013 by ETS-Lindgren Inc. All Rights Reserved. No part
of this document may be copied by any means without written permission
from ETS-Lindgren Inc.
Trademarks used in this document: The ETS-Lindgren logo is a trademark of
ETS-Lindgren Inc; 3M and Scotch‑Brite are trademarks of 3M; Rulon is a
registered trademark of Saint-Gobain; Masonite is a registered trademark of
Masonite International Corporation.
Revision Record
MANUAL,DKE DOOR MAINT,W/MSDS SHEETS | Part #100514, Rev. D
ii
Revision
Description
Date
A
Initial Release
June, 1994
B–C
Initial Release; edit; updates
February, 2003
D
Rebrand
April, 2013
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Table of Contents
Notes, Cautions, and Warnings ................................................ v
1.0 Introduction .......................................................................... 7
ETS-Lindgren Product Information Bulletin ................................................. 7
2.0 About Maintenance .............................................................. 9
Replacement Parts ..................................................................................... 9
Service Procedures .................................................................................. 10
3.0 Regular Maintenance Schedule ........................................ 11
Required Tools and Supplies (Not Included) ............................................. 11
For Weekly Maintenance .................................................................. 11
For Monthly Maintenance.................................................................. 11
For Six-Month Maintenance .............................................................. 11
For Annual Maintenance ................................................................... 11
Weekly: Door Leaf Knife Blades................................................................ 12
Monthly: Receiver Channels ..................................................................... 12
Every Six Months: Contact Fingers, Hinges/Latch Bar .............................. 13
Contact Fingers ................................................................................ 13
Hinges/Latch Bar .............................................................................. 14
Annually: Finger Stock, Door Handle, Latch Bar ....................................... 15
4.0 Finger Stock Replacement ................................................ 17
Required Tools and Supplies (Not Included) ............................................. 17
Replacement Steps .................................................................................. 18
5.0 Door Handle/Spindle Assembly Maintenance ................ 21
Required Tools and Supplies (Not Included) ............................................. 21
Maintenance Steps ................................................................................... 22
Steps to Clean .................................................................................. 22
Steps to Adjust.................................................................................. 23
6.0 Latch Bar Maintenance...................................................... 25
Required Tools and Supplies (Not Included) ............................................. 25
Maintenance Steps ................................................................................... 25
7.0 Hinge Adjustment and Door Alignment ........................... 27
Required Tools and Supplies (Not Included) ............................................. 27
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iii
Adjustment/Alignment Steps ..................................................................... 28
Appendix A: Warranty ............................................................. 29
iv
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Notes, Cautions, and Warnings
Note: Denotes helpful information intended to
provide tips for better use of the product.
Caution: Denotes a hazard. Failure to follow
instructions could result in minor personal injury
and/or property damage. Included text gives proper
procedures.
Warning: Denotes a hazard. Failure to follow
instructions could result in SEVERE personal injury
and/or property damage. Included text gives proper
procedures.
See the ETS-Lindgren Product Information Bulletin for safety,
regulatory, and other product marking information.
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1.0 Introduction
Each ETS-Lindgren Double Knife Edge (DKE) Recessed Channel
Mechanism (RCM) Door is manufactured to precise standards and tolerances
and is designed for high performance and durability. This guide provides the
steps to perform periodic maintenance that is intended to prevent a problem from
occurring in the future, eliminate the need for costly repairs, and to avoid costly
down time.
ETS-Lindgren Product Information Bulletin
See the ETS-Lindgren Product Information Bulletin included with your shipment
for the following:

Warranty information

Safety, regulatory, and other product marking information

Steps to receive your shipment

Steps to return a component for service

ETS-Lindgren calibration service

ETS-Lindgren contact information
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Introduction
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Introduction
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2.0 About Maintenance
Before performing any maintenance,
follow the safety information in the
ETS-Lindgren Product Information
Bulletin included with your shipment.
WARRANTY
Maintenance of the DKE RCM Door is
limited to the components described in
this guide.
Warranty may be void if the instructions
in this maintenance guide are not
followed.
If you have any questions concerning
maintenance, contact ETS-Lindgren
Customer Service.
Replacement Parts
ETS-Lindgren may substitute a similar part or new part number with
the same functionality for another part/part number. Contact
ETS-Lindgren for questions about part numbers and ordering parts.
Following are the part numbers for ordering replacement parts for the
ETS-Lindgren Double Knife Edge RCM Door.
Part Description
Part Number
DKE Door Maintenance Kit
206656
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About Maintenance
9
Service Procedures
For the steps to return a system or system component to ETS-Lindgren for
service, see the Product Information Bulletin included with your shipment.
10
About Maintenance
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3.0 Regular Maintenance Schedule
Before performing maintenance, follow the
safety information in the ETS-Lindgren
Product Information Bulletin included with your
shipment.
When working with solvents, always use
eye protection and protective clothing, and
make sure there is proper ventilation.
Required Tools and Supplies (Not Included)
FOR WEEKLY MAINTENANCE

Clean, soft cloths

Scour pads (for example, a 3M™ Scotch-Brite™ pad)

Acetone or similar solvent
FOR MONTHLY M AINTENANCE

Clean, soft cloths

3-inch putty knife

Acetone or similar solvent
FOR SIX-MONTH M AINTENANCE

Clean, soft cloths

Emery cloth sandpaper, 320 grit

3-inch putty knife

Acetone or similar solvent

1/8-inch tempered Masonite® or 3-inch x 6-inch piece of plastic sheet

Light machine oil

Lightweight grease
FOR ANNUAL M AINTENANCE
See maintenance procedures on page 17, page 21 and page 25.
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Regular Maintenance Schedule
11
Weekly: Door Leaf Knife Blades
1.
Use a scour pad to remove residue and clean the inner and outer
double knife blades on the door leaf.
2.
Clean the blades with a soft cloth soaked with acetone or similar
solvent.
Monthly: Receiver Channels
Do not slide putty knife and cloth across
finger stock when performing these steps.
Do not use an excessive amount of solvent. The contact fingers on the
door are attached with adhesive. Any over-application of solvent other
than as described in the following steps may disrupt the adhesive and
cause the contact fingers to fall off.
If a source of clean, dry, oil-free air is available, it may be applied to
speed drying time.
1.
Lightly dampen a clean, soft cloth with solvent.
2.
Completely cover the blade portion of a 3-in putty knife.
3.
To remove built-up dirt from the contact fingers, start at the top center
of the door:
4.
12

For the upper and lower horizontal receiver channels—Insert the
putty knife with cloth into the receiver channel and work it towards a
corner with an in-and-out motion; repeat in the opposite direction.

For the vertical receiver channels—Insert the putty knife with cloth
into the top of the channel and work down to the bottom; repeat for the
opposite channel.
Allow the solvent to evaporate, and then repeat the entire procedure.
Regular Maintenance Schedule
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Every Six Months: Contact Fingers, Hinges/Latch Bar
Do not move the sanding assembly side-to-side
or up-and-down. The edges of the sanding
paper will snag and damage the contact fingers.
CONTACT FINGERS
1.
Fold a piece of 320 grit emery cloth over a section of 1/8-in tempered
Masonite or a 3-in x 6-in piece of plastic sheet with the sanding
surfaces facing out.
2.
Slide the sanding assembly straight into and between the rows of
contact fingers located in the double knife edge receiver. With two or
three strokes, burnish the surfaces of the contact fingers.
3.
Move to the next section, and with a 1/2-in overlap, repeat this
procedure around the entire perimeter of the double knife edge
receiver. Be sure to burnish both rows of finger stock.
4.
Remove the residue with a soft cloth soaked with solvent and wrapped
around a 3-in putty knife, as described in the monthly maintenance
steps on page 12.
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Regular Maintenance Schedule
13
HINGES/LATCH BAR
Do not lubricate hinges on door models manufactured after
January, 1989; these hinges have self-lubricating Rulon® bearings
and require no additional lubricant. The steps in this section apply only
to door models manufactured prior to January, 1989.
Do not lubricate the door handle shaft assembly on any door model.
14

Lubricate hinges with a few drops of light machine oil. Wipe off any
excess oil.

Remove the latching mechanism protective cover from the door leaf
and lubricate the nine bearings on the latch bar assembly with one
drop of light machine oil. Wipe off any excess oil.

Apply an ample amount of lightweight grease to the two latch bar
guide blocks.

Check periodically for any loose bolts and any wear or play on the
door handle/spindle assembly. See page 15 for disassembly,
assembly, and adjustment procedures.
Regular Maintenance Schedule
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Annually: Finger Stock, Door Handle, Latch Bar
The necessity to replace finger stock varies, depending on
environmental conditions and door use. For optimum RF performance,
replace finger stock every one to two years.

(Optional) Replace the finger stock around the entire perimeter of the
recessed contact mechanism (RCM). See page 17 for the steps to
replace finger stock.

Disassemble and clean the door handle/spindle assembly following the
steps on page 21.

Disassemble and lubricate the latch bar assembly following the steps
on page 25.
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Regular Maintenance Schedule
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Regular Maintenance Schedule
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4.0 Finger Stock Replacement
Before performing maintenance, follow the
safety information in the ETS-Lindgren
Product Information Bulletin included with your
shipment.
When working with solvents, always use
eye protection and protective clothing, and
make sure there is proper ventilation.
The necessity to replace finger stock depends on environmental
conditions and door use. For optimum RF performance, replace
finger stock every one to two years.
Required Tools and Supplies (Not Included)

Hex key

Clean, soft cloths

Scour pads (for example, a 3M™ Scotch-Brite™ pad)

Acetone or similar solvent

Emery cloth sandpaper, 320 grit

Cotton or surgical gloves

Wide blade putty knife

Heat gun
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Finger Stock Replacement
17
Replacement Steps
1.
Use a hex key to remove the cap head screws (approximately 80) from
the removable brass center bars located in the center of the recessed
channel mechanism (RCM).
Mark the center bars left, right, top and bottom for replacement.
2.
Strip away the contact fingers from each brass center bar; strip the
finger stock from both sides of the RCM receiver channel. The width of
the bronze channel allows ample space to achieve this task.
Discard the used finger stock. Do not reuse.
3.
Remove any adhesive residue with solvent. Clean the exposed
surfaces of the brass center bar and the RCM channel with a
scour pad.
4.
Use a 320 grit emery cloth to etch the surfaces of the brass and bronze
components where the new finger stock will be installed, and then
clean the surfaces with solvent.
Because fingerprints will prematurely etch the
material and reduce the effective performance,
always wear cotton or surgical gloves to handle
finger stock.
5.
18
Replace the finger stock with ETS-Lindgren finger stock
(part number 204701). Beginning in one corner, strip away the
protective paper backing from the two-foot length of finger stock and
attach the adhesive-backed strip to the side of the bronze RCM
channel.

Make sure that the end of the finger stock material compresses into the
RCM, and that each strip is in a straight line.

Align the edge of each strip with the leading top edge of the
RCM channel.

Position the two rows of replacement finger stock around the perimeter
of the RCM channel. Use a wide blade putty knife to apply pressure to
each section of material to make sure the adhesive is uniformly
attached to the bronze surface.
Finger Stock Replacement
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
Attach finger stock to each side of the removable brass bar and then
reinstall.

With the RCM reassembled and in proper alignment, use a heat gun to
apply hot air, taking care to not overheat. Apply sufficient heat to bring
the adhesive backing to a semisoft state, allowing the adhesive to grip
and set into the previously-etched surface.

Allow ample time for the heated metal to return to room temperature
before engaging the door leaf.
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Finger Stock Replacement
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Finger Stock Replacement
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5.0 Door Handle/Spindle Assembly Maintenance
Before performing maintenance, follow the
safety information in the ETS-Lindgren
Product Information Bulletin included with your
shipment.
When working with solvents, always use
eye protection and protective clothing, and
make sure there is proper ventilation.
Required Tools and Supplies (Not Included)

Hex key

Screwdriver(s)

Clean, soft cloths

Acetone or similar solvent

Scour pads (for example, a 3M™ Scotch-Brite™ pad)

Fine sandpaper (if required)

Lightweight grease

#7 drill (if required)
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Door Handle/Spindle Assembly
Maintenance
21
Maintenance Steps
STEPS TO CLEAN
1.
Use a hex key to remove the cap head screw and lock washer from the
front door handle center.
2.
Remove the eight screws that secure the latch bar protective cover to
the door leaf. Remove the cover and set it aside.
3.
Loosen the hex drive set screw in the rear door handle. For door
models manufactured after January, 1989, remove the cap head bolt
and lock washer, and then the rear door handle.
4.
From the rear side of the door leaf, remove the thrust bearing, two
hardened ground washers, and the RF mesh gasket from the 1-in steel
door shaft.
5.
Push the door drive shaft to the front of the door leaf and remove the
remaining assembly, which consists of the steel drive shaft, drive gear
and a thrust bearing, and two hardened ground washers.
The ball bearing race is press-fit into the brass bearing retainer and
should only be replaced if excessive wear is apparent.
6.
7.
If necessary, remove the 4-in brass bearing retainers by removing the
four center-bored cap head screws on each side. Before removal,
mark the position of each retainer assembly on both sides.

Soak the bearing retainer assemblies in solvent to remove all traces of
lubricant.

Reassembly requires the use of the door drive center shaft for
alignment.
Clean all components with solvent and polish the surfaces with a
scour pad.
Clean the interior of the 2-in bronze center bushing mounted in the
door leaf panel and burnish with fine sandpaper, if needed.
22
Door Handle/Spindle Assembly
Maintenance
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8.
Reassemble by following these steps in reverse order.
9.
Realign the drive gear and the gear rack on the latch bar with the
indexing marks on both components for the proper door handle
indexing arc.
10. Lubricate the gear teeth with grease.
STEPS TO ADJUST
1.
Adjust the tension on the door handle spindle assembly by tightening
the cap head bolt on the rear handle to a point where the RF gasket is
compressed for RF integrity; the handle will have a slight drag.
2.
For door models manufactured after January, 1989: Tighten the
locking set screw on the door handle. If the door handle does not have
a set screw feature, it can be retrofitted by drilling with a #7 drill and
tapping the hole with a 1/4–20 tap for a 1/4–20 set screw. The set
screw will prevent the door handle from working loose.
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Door Handle/Spindle Assembly
Maintenance
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Door Handle/Spindle Assembly
Maintenance
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6.0 Latch Bar Maintenance
Before performing maintenance, follow the
safety information in the ETS-Lindgren
Product Information Bulletin included with your
shipment.
Required Tools and Supplies (Not Included)

Hex key

Screwdriver(s)

Clean, soft cloths

Lightweight grease

Grease gun
Maintenance Steps
1.
Use a hex key to remove the cap head screw and lock washer from the
front door handle center.
2.
Remove the eight screws that secure the latch bar protective cover to
the door leaf. Remove the cover and set it aside.
3.
Remove the covers of the latch bar guide blocks and lubricate with
lightweight grease.
4.
Repack the ball bearing race on each center bearing with grease;
these are mounted on the crossbars of the latch bar at three locations.
5.
For door models manufactured after January, 1989: Loosen the locking
set screws, retaining the ball bearing cam followers at six locations on
the crossbars of the latch bar assembly. With a straight slot
screwdriver or a hex key, remove the six cam followers. Apply grease
with a grease gun to the threaded stud end until new lubricant appears
at the bearing end.
Reassemble the cam followers and lock down the set screws.
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Latch Bar Maintenance
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Latch Bar Maintenance
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7.0 Hinge Adjustment and Door Alignment
Before performing maintenance, follow the
safety information in the ETS-Lindgren
Product Information Bulletin included with your
shipment.
Under normal shipping and operating
conditions, the door frame and leaf assembly
should never become misaligned. However, if
unusual or extreme conditions occur, consult
ETS-Lindgren prior to attempting any corrective
action.
Required Tools and Supplies (Not Included)

Wrenches

Blocks

Pipe clamps

Hex key (if required)

Screwdrivers

Drift pin
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Hinge Adjustment and Door Alignment
27
Adjustment/Alignment Steps
The door frame and leaf are factory-aligned with precision jigs. The
bolts securing these components together (grade 8) with the heavy
duty hinges are torqued to 80–100 in-lb. The holes in the door leaf are
bored oversize to allow the door leaf to move approximately 1/16 inch
to the left, right, up, and down.
1.
2.
3.
With the door in the closed position, loosen three of the four bolts
securing the hinge plate to the door leaf.

With blocks and pipe clamps, move the door leaf edge in the required
direction.

With the door leaf repositioned, retighten the three hinge plate bolts.
For door models manufactured after January, 1989: The Rulon™ hinge
thrust bearings have an anticipated life of five to ten years under
normal conditions. If it becomes necessary to replace the bearings,
work on one hinge at a time to maintain the proper alignment of the
door frame and leaf.

With the door in the closed position and the handle in the locked
position, remove the hinge plate from one of the hinge assemblies by
removing the eight cap head bolts.

Release the two locking set screws at the rear of each hinge arm and
remove the hinge arms and the hinge pin from the hinge base.

With a small flat blade screwdriver, remove the Rulon bearings from
the hinge base. Replace with new bearings and discard the old
bearings.

Reassemble the hinge assembly by following these steps in
reverse order.
Older steel hinge assemblies (black): These assemblies have two ball
bearing sets in each hinge.

With the door in the closed and locked position, remove one hinge
assembly entirely from the door frame and leaf.

The ball bearing races are press-fit into the steel hinge barrel; drive the
bearing free with a drift pin, and then replace.

28
Repack the bearing with grease and reassemble.
Hinge Adjustment and Door Alignment
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Appendix A: Warranty
See the Product Information Bulletin included with your shipment for
the complete ETS-Lindgren warranty for your DKE RCM Door.
DURATION OF WARRANTIES FOR DKE RCM DOOR
All product warranties, except the warranty of title, and all remedies for warranty
failures are limited to one year.
Product Warranted
Duration of Warranty Period
Double Knife Edge (DKE) Recessed
Channel Mechanism (RCM) Door
1 Year
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Warranty
29
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