Step 2. From the outside of the bearing assembly, fully depress the aligning pin. The aligning pin must be fully depressed in order to remove the outside sleeve.
Step 3. Unscrew the outside collar and remove the outside sleeve from the bearing assembly.
Step 4. Slide the aligning pin out of the bearing assembly. The align pin serves two purposes -- retaining the latch bolt assembly and the outer sleeve.
Step 5. Slide the latch bolt assembly out of the bearing assembly. The T-Zone is disassembled, ready for installation.
Retrofitting The Door
The door must be retrofit from a mortise lock configuration to accommodate the T-Zone cylindrical lock configuration, which requires a 2-1/8" cross bore opening at the 2-3/4" backset. The Don-Jo Remodeler plates will cover the existing mortise lock hardware openings. The filler plate will convert the mortise pocket opening to accommodate the latch bolt assembly.
Step 1. Position the filler plate into the mortise pocket opening. Using the latch bolt assembly as a guide, determine the best location for the 2-1/8" diameter cross bore opening at the 2-3/4" backset. Avoid the lock support clips if possible.
Remember: The filler plate latch bolt location is offset, which means it can be located in one of two positions; higher or lower on the door.
Step 2. Mount the filler plate into the edge of the door using the two Phillips head screws.
Step 3. Mark the center for the 2-1/8" diameter cross bore opening. Use the center of the latch bolt opening in the plate.
Step 4. Use a 2-1/8" diameter hole saw to carefully drill through the door skin and the reinforcement plate.
Step 5. Drill through each door face from the outside to ensure an accurate cross bore opening. Remove any burrs using a file.
Step 6. Insert the bearing assembly into the door, making sure it slides freely and can be rotated. Remove bearing assembly and make any modifications necessary.
Step 7. Mount the filler plate into the door edge using the two black screws and the large Phillips head screw driver. Do not tighten the screws.
Step 8. Remove the mortise strike plate and install the replacement strike plate.
Installing the Lock
The door has been configured to accommodate the T-Zone retrofit. Install the lock:
Step 1. Insert the bearing assembly into the door with the opening for the latch assembly facing the filler plate.
Step 2. Slide the latch assembly into the bearing assembly. Make sure the latch seats within the bearing assembly.
Step 3. Insert the aligning pin into bearing assembly from the secured (outside) side of the lock. If necessary, slightly rotate the bearing assembly to accommodate the latch bolt assembly. Make sure the aligning pin slides completely into the bearing assembly cutout.
The alignment pin performs two functions. First, it locates/secures the latch assembly. Second, it eliminates unauthorized access by removing the outside sleeve.
Step 4. Start the two Phillips head screws to secure the latch bolt assembly into the filler plate.
Step 5. Install the outside sleeve onto the bearing assembly with the lever retaining dimple facing toward the latch.
Since a Storeroom function lock is being installed, the red outer sleeve driver tip is must match-up prior to assembly. The locking piece must be in the unlocked position prior to assembly. To unlock, insert a flat blade screwdriver into the slotted cam opposite the driver tip and rotate until the locking piece is towards the center of the outside sleeve.
Step 6. Thread the outside sleeve collar onto the bearing assembly. Tighten until there is a notch in the collar directly above the alignment pin. Test the operation using a flat blade screwdriver as described above.
Step 7. Insert the inside sleeve into the bearing assembly with the dimple facing toward the latch.
Step 8. Thread the inside sleeve collar onto the bearing assembly. As the collar is tightened, the alignment pin will slide into the notch in the outside collar. This locks the outside sleeve collar in place, preventing removal of the outside lever and sleeve from the exterior side of the door.
Step 10. Place the Don-Jo Remodeler plate onto the outside face of the door.
This modification provided the capability of a deadbolt and dead latch in one lock (mortise) mechanism while maintaining the integrity of the door.