Yeah, we have keyed in on operator awareness of the proper use of the handles... Seems to have improved.

we have about 60 of these trucks and its very common

problemis that the handle covers are verry thin and fragile

they are a pain in the butt to replace due to a dual rollpin lock

Is this a freezer operation? I have replaced a few of these, but not as often as you are replacing them. Do you have all the screws in that hold the handle halves together and are they the right length? I would order the screws next time you replace the handle halves just to make sure. Seems to me like there was someting you had to trim out of the handle when Crown changed the design if you had an older harness or what I call the thumball kit that goes through the handle. This should be in the instructions that come with the handle halves.
This could be how the operators are using the truck or maybe somethiing that is unique to your application or something in the air. I once worked in a large bakery that could not keep the rubber on the twist grips of a PE. They just quit replacing the grips and ran it with the hard plastic under the rubber grip.

It is very possilbe that this could be abuse.

Apparently across a fleet. I don't have that complete information yet but apparently this particular truck by itself has had the handle replaced 4 years in a row. It is used by multiple users on two shifts.

Is this on one particular truck,or across a fleet of RR5000 series trucks? I've replaced a few(Hundred) multi-task handle assemblies,in our area,ove the years. But only replaced two that where broke around the thumbwheel area.

Thanks for replying!

No, I'm refering to the plastic housing itself, upper part of it, near the "ball" area that houses the thumb wheel selector. Any input is appreciated, thanks.

Are you talking about the outer covering coming loose from the inner plastic base?