Kaba SIMPLEX 5000 CYLINDRICAL Installation Instructions Manual

INSTALLATION INSTRUCTIONS

SIMPLEX®5000 CYLINDRICAL

TABLE OF CONTENTS

Exploded Install Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

A. Door Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

B. Lock Handing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

C. Door Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

D. Installing The Passage Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

E. Installing Outside Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

F. Installing Inside Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

G. Installing The Inside Lever/Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

H. Changing Key-In-Lever/Knob (KIL/KIK) Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

I. Installing/Removing Outside Lever/Knob (KIL/KIK models only) . . . . . . . . . . . . . . . . . .8

J. Installing/Removing Outside Lever/Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

(Interchangeable/Removable Core models)

K. Testing The Operation Of The Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

L. Installing The Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

M. Changing Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

N. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

O. How To Reset A Lost Or Unknown Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

P. Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

1) 2) 3)

Warning

The combination of this lock has been factory preset; 2 and 4 depressed at
the same time, then 3 and then ENTER. For your security, the combination
must be changed at time of installation.

OPERATION

2

TOOLS REQUIRED

• Safety glasses

• Electric drill (variable speed)

• Awl or center punch

• 2

1

⁄8" (54 mm) hole saw pilot drill

• 1" (25 mm) hole saw pilot drill

•

1

⁄4" (7 mm) drill bit

• 1" (25 mm) wood chisel

• Hammer

• Phillips head screw driver

• Small flat blade screwdriver

Inside Lever

Mounting Screws

I

nside Unit

Assembly

Outside Unit

Assembly

Outside Lever
Assembly

3

/4" (18mm) Screws

Latch

1" (25mm) Screws

Allen Wrench

Set Screw

ASA Strike

Release/Combination
Change Tool

Model 502x (shown)

The Simplex 5000 is a non-handed lock that is preassembled for
left-hand installations. It is field reversible.

For technical assistance please call

1.800.849.TECH (8324) or 336.725.1331

Warnings and Cautions

Important: Carefully inspect windows, door frame, door, lights, etc., to

ensure that the recommended procedures will not cause damage.
Kaba Access Control’s warranty does not cover damages caused by
installation.

Caution: Wear safety glasses when preparing door.

3

A. DOOR PREPARATION

A-1 Place paper template (supplied) onto door

and mark for holes. Drill the four

1

⁄4" (7

mm) holes first. Next drill the 2

1

⁄8" (54
mm) cross bore hole. Drill the 1" (25 mm)
hole last.

A-2 For Models 504x & 505x only. When

installing Model 502x, skip to step A-4.

Passage feature models require an
additional 1” (25 mm) hole in the door face
(see “a” in the illustration to the right).

A-3 For Models 503x & 505x only. When

installing Models 502x or 504x models,
skip to step A-4. Inside code change models

require an additional 1” (25 mm) hole in the
door face (see “b” in the illustration).

A-4 Mortise door edge for latch unit faceplate (c)

1

⁄8" (3 mm) deep to dimensions shown. Insert
latch unit into the 1" (25 mm) hole, making
certain that the latch bolt bevel faces
direction of closing door.

Note: If using a

3

⁄4" (19 mm) latch, the edge of the
latch bore hole must be prepped to accomodate
the anti-friction hinge. (The location of the anti­friction hinge depends on the door handing).

A-5 Secure the latch to the door using two

3

⁄4"
(19 mm) combination screws (d) supplied.
Latch unit faceplate must be flush with door (e).

B. LOCK HANDING

The Simplex 5000 is a non-handed lock that is
preassembled for left-hand door installations.

B-1 Determine the hand of your door. For left

hand doors, proceed to Section C.
For right hand doors, follow steps in B-2.

4

4

x

1

⁄4"

b 1" (for models
503x & 505x)

a

1" (for models

5

04x & 505x)

b 1" (for models
503x & 505x)

Mortise approx.

5

⁄16" (8 mm)

extra depth to
allow clearance
of anti-friction
hinge

b 1" (for models
503x & 505x)

a 1" (for models
504x & 505x)

a 1" (for models
504x & 505x)

2

1

⁄8"

1"

1

1

⁄8"

c

Anti-friction hinge

Anti-friction device

e

d

2

1

⁄4"

Left Hand Left Hand Reverse Bevel

R

LEFT HAND DOOR

Right Hand Right Hand Reverse Bevel

RIGHT HAND DOOR

c

a

b

5

B-2 Remove the two connecting screws (a) from the cylindrical drive unit (b).

Rotate cylindrical drive unit 180 degrees. Reposition spacer (c) as found
before disassembly. Remount drive unit with the two connecting screws.

C. DOOR THICKNESS

The Simplex 5000 lock is preassembled to
accommodate standard door thickness 1

5

⁄8" (41 mm)

to 2" (51 mm).

C-1 (Reference Figure A) For thinner door applications

of 1

3

⁄8" (35 mm) to 11⁄2" (38 mm) Remove and

discard the two connecting screws (a) from the
cylindrical drive unit (b). Remove and discard the
spacer (c). Remount the cylindrical drive unit using
the two shorter 1

3

⁄8" (35 mm) connecting screws

supplied.

C-2 (Reference Figure B) For thicker door applications

of 2

1

⁄8" (54mm) to 21⁄4" (57mm) Remove the two

connecting screws (a) from thecylindrical drive unit (b). Add the extra
spacer(c) supplied. Remount the cylindrical drive unitusing the same two
connecting screws (a) just removed. (Do not over tighten screws)

D. INSTALLING THE PASSAGE SET

For models 504x & 505x only. When installing non-passage models,
skip to section E.

Note: The end user may choose either a key cylinder (a) or turn knob (b)

actuator to engage the passage function.

D-1 Prior to installing the passage actuator, hold the

chosen actuator housing in one hand, and with the
other hand, rotate the key cylinder or knob
counterclockwise until it stops. If the key cylinder
actuator is used, withdraw the key, which will lock
the cylinder in this position (a detent in the turn
knob locks the cylinder).

D-2 Insert the key cylinder or turn knob assembly (a or b) into the opening

on the inside unit assembly (c). Upon completion, the arrow of the turn
knob should be pointing to the left, or the dot on the face of the key
cylinder actuator should be on the left.

D-3 Secure the passage set assembly with the spring clip (d) from the inside.

b

a

c

b

a

c

c

b

d

a

6

D-4 Rotate the knob or key cylinder (re-insert key at this

point) clockwise to test the rotation. If properly
installed, the knob or key cylinder should rotate 90
degrees clockwise so that the arrow (knob) is pointing
up or the dot (key cylinder) is at the top.

Note: Leave the actuator set in this position for installation
(if key cylinder is used, remove the key at this point).

Note: The tailpiece of the passage actuator is scored on several places to
allow you to easily break off the section that extends beyond the required
length to engage the passage set cam.

D-5 Hold the tailpiece firmly with a pair of pliers, adjacent

to the desired break line. With a second pair of pliers,
grip the tailpiece on the other side of the scored line
and bend up and down until it breaks.

E. INSTALLING OUTSIDE UNIT ASSEMBLY

Note: Installing levers/knobs to the unit assemblies before

mounting the unit assemblies may ease initial installation.

E-1 For models 504x & 505x only. When installing non-

passage models, skip to step E-2. Ensure that the passage

cam (b) is rotated counterclockwise until it stops. When
complete, the slot will be vertical.

E-2 Slide the drive unit (a) into 2

1

⁄8" (54 mm) cross bore hole
by depressing latch bolt (b) in slightly until the outside
unit assembly (c) rests flush against the door.

E-3 The drive unit (d) must engage the latch unit prongs (e)

and the shoe retractor (f) must engage the latch unit
tailpiece (g) as shown.

F. INSTALLING INSIDE UNIT ASSEMBLY

Note: Installing levers/knobs to the unit assemblies before

mounting the unit assemblies may ease initial installation.

F-1 For Models 504x & 505x only. When installing non-

passage models, skip to step F-2. Slide the drive hub (a)

into the sleeve (b), and the passage tailpiece (d) into the
passage cam slot until the inside unit assembly (c) rests
flush against the door.

b

f

g

e

d

c

a

b

c

d

a

b

7

F-2 Slide the drive hub (a) into the drive sleeve (b) until the

inside unit assembly (c) rests flush against the door.

F-3 For standard door thickness 1

5

⁄8" (41 mm) to 2" (51

mm), secure the outside and inside unit assemblies to

the door by using four 2

7

⁄8" (73 mm) screws (d)

(supplied) in all four holes as indicated.

For thinner door 1

3

⁄8" (35 mm) to 11⁄2" (38 mm),

secure the outside and inside unit assemblies to the door
by using four 2

1

⁄2" (64 mm) screws (e) (supplied) in all

four holes as indicated.

For thicker door 2

1

⁄8" (54 mm) to 21⁄4" (57 mm), secure the outside

and inside unit assemblies to the door by using four 3

1

⁄4" (82mm)

screws (f) (supplied) in all four holes as indicated.

G. INSTALLING THE INSIDE

LEVER/KNOB

Note: Installing the lever/knob assemblies to the unit

before mounting the unit assemblies, may ease initial
installation.

G-1 Insert the inside lever/knob (a) onto the unit assembly.

Secure the inside lever/knob with the

3

⁄8" (5mm) hex

screw (b) supplied using the allen wrench (c) supplied.

H. CHANGING KEY-IN-LEVER/KNOB

CYLINDER

The Simplex 5000 outside lever/knob comes preassembled with Kaba's
key-in-lever/knob cylinder (Kaba 1599). To use a different key-in-lever/
knob cylinder, follow the remaining steps in this section.

H-1 Remove KIL/KIK cylinder (a) from the outside

lever/knob (b) by removing the lever insert (e) (no
insert on knob). Remove the rubber cylinder
retainer (c) using a small screwdriver or needle
nose pliers.

c

a

b

d

, e, f

a

b

a

d

c

a

b

c

b

c

8

H-2 Determine the proper tailpiece (d) needed for

your KIL/KIK cylinder from the chart above.

You must use a KABA tailpiece. The K-2 tailpiece
is preassembled with the 1599 cylinder.

H-3 Assemble the required tailpiece (d) supplied with

your KIL/KIK cylinder. All tailpieces must be
installed vertically as shown for proper
installation.

H-4 Insert the KIL/KIK cylinder (a) into the outside

lever/knob (b) and secure it with the cylinder
retainer (c) and lever insert (e) (no insert on the
knob). The KIL/KIK cylinder should be snug and
unable to move freely.

I. INSTALLING/REMOVING

OUTSIDE LEVER/KNOB

(Key-in-Lever/Knob Models only) (For
interchangeable and removable cores,
proceed to section J)

Note: Installing lever/knob to the unit assemblies before

mounting the unit assemblies, may ease initial installation.

b

a

e

d

c

KIL Lever Sleeve

LH RH

c

Correct
Position

Incorrect
Position

f

b

a

d

c

b

a

d

e

c

vertical

Assa 65611, Australian: Kaba experT 107K5 &
Boyd KC286, Corbin-Russwin 2000-03, Kaba
1599, Schlage 23-001, Schlage Primus 20-760,
Kaba Peaks 1099

Medeco 20W200H1

Arrow C100, Sargent 10 LINE

Marks

Abloy 5277, Abloy 5477, Assa 65691,
Kaba 15396, Kaba Gemini 4730

KIL/KIK CYLINDERTAILPIECE

K1

K3

K2

K4

K5

9

I-1 Make certain the lever catch is up as shown (c).

The lever catch should be flush around the
outer diameter of the outside driver. Make
certain the lever sleeve (f) is rotated to
properly mate with the outside lever/knob.

I-2 Insert one of the supplied keys (a) into the

outside lever/knob (b) and rotate key
counterclockwise 45 degrees.

I-3 Insert the outside lever/knob (b) until it is flush to the

outside unit assembly (levers fit closer than knobs).
Secure the outside lever/knob by rotating the key
clockwise 45 degrees to the horizontal position. Remove key.

Note: To remove the outside lever/knob from
the outside unit assembly, follow steps below.

I-4 Insert one of the supplied keys (a)

into the outside lever/knob and
rotate it counterclockwise 45
degrees. Insert the release tool (d)
into the small hole (e) under the
lever/knob as shown. Gently push
the lever catch up until it clicks.
Remove tool, then remove the
outside lever/knob.

J. INSTALLING/REMOVING

OUTSIDE LEVER/KNOB

(Interchangeable/Removable Core Models)

Note: Installing levers/knobs to the unit assemblies before

mounting the unit assemblies, may ease initial installation.

J-1 Make certain the lever catch is up as shown (c). The

lever catch should be flush around the entire diameter
of the outside driver. Make certain the lever sleeve (f) is
rotated to properly mate with the outside lever/knob.

J-2 Insert the outside lever/knob (a) until it

is flush to the outside unit assembly (b)
(levers fit closer than knobs). Insert the
release tool (d) (or screw- driver) into
the outside lever/knob as shown, and
slide the lever catch down until it clicks.

Note: For all interchangeable/removable
cores except ASSA/Medeco/Yale, proceed
to section J-3. For ASSA/Medeco/Yale
cores, skip to section J-5.

c

Correct
Position

Incorrect
Position

a

b

45º

b

a

IC Lever Sleeve

LH RH

f

e

a

45º

d

d

e

a

b

b

d

d

a

a

KABA SIMPLEX®/E-PLEX®5x00 SERIES
LIMITED WARRANTY

Kaba Access Control warrants this product to be free from defects in material
and workmanship under normal use and service for a period of three (3) years.
Kaba Access Control will repair or replace, at our discretion, 5000 Series Locks
found by Kaba Access Control analysis to be defective during this period. Our
only liability, whether in tort or in contract, under this warranty is to repair or
replace products that are returned to Kaba Access Control within the three (3)
year warranty period.

This warranty is in lieu of and not in addition to any other warranty or
condition, express or implied, including without limitation merchantability,
fitness for purpose or absence of latent defects.

ATTENTION: This warranty does not cover problems arising out of improper
installation, neglect or misuse. All warranties implied or written will be null and
void if the lock is not installed properly and/or if any supplied component part
is substituted with a foreign part. If the lock is used with a wall bumper, the
warranty is null and void. If a doorstop is required, we recommend the use of a
floor secured stop.

The environment and conditions of use determine the life of finishes
on Kaba Access Control products. Finishes on Kaba Access Control products
are subject to change due to wear and environmental corrosion. Kaba Access
Control cannot be held responsible for the
deterioration of finishes.

Authorization to Return Goods

Returned merchandise will not be accepted without prior approval. Approvals
and Returned Goods Authorization Numbers (RGA Numbers) for the 5000
Series are available through our Customer Service department in Winston­Salem, NC 800.849.8324. The serial number of a lock is required to obtain
this RGA Number. The issuance of an RGA does not imply that a credit or
replacement will be issued.

The RGA number must be included on the address label when material
is returned to the factory. All component parts including latches and strikes
(even if not inoperative) must be included in the package with return. All
merchandise must be returned prepaid and properly packaged
to the address indicated.

KABA ACCESS CONTROL

2941 INDIANA AVENUE

WINSTON-SALEM, NC 27199-3770

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

BUSINESS REPLY MAIL

FIRST-CLASS MAIL

PERMIT NO. 1563

POSTAGE WILL BE PAID BY ADDRESSEE

WINSTON-SALEM, NC

Thank you for purchasing our product. In order to

protect your investment and to enable us to better

serve you in the future, please fill out this registration

card and return it to Kaba Access Control, or

register online at www.kabaaccess.com.

This lock will be used in what type of facility?

 Commercial Building  Industrial/Manufacturing  Airport

 College/University  Government/Military  School/Educational

 Hospital/Healthcare  Other (please specify)

What area is being secured with this lock? (e.g. Front Door, Common Door, Exercise Room)

This lock is:

 New Installation

 Replacing a conventional keyed lock

 Replacing a Kaba Mechanical Pushbutton Lock

 Replacing a Kaba Electronic Access Control

 Replacing a Keyless Lock other than Kaba

How did you learn about Kaba Access Control Pushbutton Locks?

 Advertisement  Previous Use  Internet/Web  Another Use

 Locksmith  Maintenance  Training Class  Other (please specify)

What was your reason for buying this lock?

Who installed your lock?

 Locksmith  Maintenance  Other

 Check here if you would like more information on Kaba Access Control locks.

Name

Position

Company

Address

City

State ZIP (Postal Code) Country

Phone

Email

Name of Dealer Purchased From

Date of Purchase

Lock Model Number

REGISTRATION CARD

Notes

14

J-3 Insert the supplied tailpiece (e) with the flat

installed vertically into the outside lever/knob
(b) as shown. Make certain you rotate the
tailpiece so that it aligns with the rear of the
core. For screw cap type cores (Schlage) (g),
the tailpiece must be assembled to the core
first, with the tailpiece vertically as
shown. Insert the core into the
outside lever/knob.

Note: To remove the outside lever/knob from the
outside unit assembly, follow the steps below.

J-4 Remove the interchangeable core (a).

Then remove the tailpiece (b).

Note: You may want to use needle nose pliers for
some tailpieces.

Insert the release tool (d) into the small
hole (f) under the lever/knob as shown.
Gently push lever/knob catch up until it
clicks. Remove tool, then remove outside
lever/knob (b).

J-5 For ASSA/Medeco/Yale interchangeable/

removable cores, the tailpiece must be
prepped for the desired length before
installation.

Note: When using a Yale core on a cylindrical latch application, measure the
door thickness of the intended application.

J-6 Notice the score marks on the flat portion

of the ASSA/Medeco/Yale tailpiece. Using
the diagram to the right, locate the score
mark on your tailpiece that matches your
core prep for the intended application, and
break the tailpiece off accordingly.

Note: Using two pairs of pliers, break the
tailpiece to the desired length of the intended
application by holding one pair of pliers on the
good side of the score mark and a second pair on
the other side of the score mark. Slowly move the
second pair of pliers up and down until the
unneeded portion of the tailpiece breaks free.

b

a

b

b

b

a

f

d

f

d

vertical

YALE 6 & 7 PIN,
CYLINDRICAL – THIN DOOR

(1

3

⁄8" (35 mm) to 11⁄2" (38 mm))

(DO NOT SHORTEN TAILPIECE ­For 1

5

⁄8" (41 mm) to 21⁄4" (57 mm))

ASSA/MEDECO 5, 6 & 7 PIN,
CYLINDRICAL – DO NOT SHORTEN
TAILPIECE

ASSA & MEDECO 6 PIN,
EXIT & MORTISE

MEDECO 5 PIN,
EXIT & MORTISE

YALE 6 & 7 PIN,
EXIT & MORTISE

b

b

g

e

e

15

J-7 Insert the ASSA/Medeco/Yale tailpiece (e) vertically

into the outside lever/knob as shown. Make certain
that you rotate the tailpiece slightly so that it will
align with the interchangeable/removable core.
Insert the interchangeable/removable core into the
outside lever/knob.

Note: To remove the outside lever/knob from
the outside unit assembly, follow steps below.

J-8 Remove the interchangeable/removable core.

Then remove the tailpiece (e).

Note: You may want to use needle nose pliers
for some tailpieces.

J-9 Insert the lever release tool (d) into the

small hole (f) under lever/knob as shown.
Gently push lever catch up until it clicks.
Remove tool, then remove outside lever/
knob (b).

K. TESTING THE OPERATION OF

THE LOCK

K-1 Rotate inside lever/knob and hold. Ensure that the latch is fully retracted

and flush with the latch faceplate. Release the inside lever/knob; the
latch should be fully extended.

K-2 For Models 504x & 505x only. When installing non-passage models,

skip to step K-4. Ensure that the key cylinder or knob of the passage

actuator is set so that the arrow or dot is at the top. Rotate outside
lever/knob and hold. Ensure that the latch is fully retracted and flush
with the latch faceplate. Release outside lever/knob: the latch should be
fully extended.

K-3 Rotate passage actuator counterclockwise so that the arrow or dot is to

the left. Then rotate outside lever/knob. The latch should not move.

K-4 Enter the factory-set combination: Depress buttons 2 and 4 at the same time

(& release), then depress button 3 (& release), then depress the “ENTER”
button (& release

). You should feel a slight click as each button is depressed.

K-5 Rotate outside lever/knob and hold. Ensure that the latch is fully retracted

and flush with the latch faceplate. Release the outside lever/knob; the
latch should be fully extended. Press the “ENTER” button and release,
then rotate outside lever/knob. The latch should NOT

retract.

K-6 Insert one of the (supplied) keys into the outside lever/knob. Rotate key

counterclockwise

to stop position and hold. Ensure that the latch is fully
retracted and flush with the latch faceplate. Rotate key clockwise to
horizontal position and remove key. The latch should be fully extended.

f

d

f

d

b

e

b

e

16

L. INSTALLING THE STRIKE

Note: The latch and strike provided must be used.

L-1 Mark location of strike on the door frame, making

certain that the strike opening is aligned (a) with
the latch bolt.

L-2 Mortise doorframe for strike

3

⁄3

2

" (3 mm)
deep minimum to dimensions shown.
Secure strike (b) to the door frame using
two 1" (25 mm) combination screws (c)
(supplied).

M. CHANGING COMBINATIONS

Note: The factory set combination of your new 5000 series: Press “2” and

“4” at the same time, then release. Press “3”, then release. Press the
“ENTER” button, then release. For your security, the factory set

combination MUST BE changed when lock is installed.

The combination can be easily changed using one to five of the lock’s buttons
in any order in the combination. Each button can only be used once. Note:

Three or more non-sequential button combinations are recommended for
higher security. Also, two or more buttons may be pushed together (at the

same time) as part of your new combination.

CAUTION: The door MUST BE open during this entire procedure.

Note: The combination change can be done without removing lock from door.
Ensure that the door is open during this procedure. Rotate the outside
lever/knob (d) once to stop position and release to reset the lock the latch
should not retract.

M-1 Press the existing combination (b) followed by the ENTER button (c)

and release; do not

turn the lever/knob.

Note: Determine if you have an interior/exterior code
change, and follow appropriate procedure below.

Exterior Combination Change

M-2 Insert the release tool (a) through hole in

number pad and gently lift up loop end of the
tool to depress the code change button until
you hear a click; remove tool and do not

press

any buttons (proceed to M-4).

c

b

a

d

e

a

c

b

11⁄4"

(31mm)

4

7

⁄8" (124mm)

3

3

⁄8" (84mm)

17

Interior Combination Change

M-3 Unscrew special torx screw from inside housing

using supplied torx wrench. Enter your existing
combination, and depress and release the
“ENTER” button. Insert longer end of the same
torx wrench through the opening until it engages
with the mating part. Turn wrench counter­clockwise (using minimal force) approximately 90
degrees, until it clicks. Return wrench to initial position.
Remove wrench and replace torx screw.

M-4 **This Step Is Very Important** Rotate lever/ knob (d)

once, and only once to clear the old combination; the latch

(e) will retract; release the lever/knob.

M-5 Press in your new combination (b) followed by the

ENTER button (c) and release.

M-6 Rotate the lever/knob (d) to verify that the latch (e) retracts

confirming the validity of the new combination (if you try the

old combination now, it should not work).

IMPORTANT: The “ENTER” button must be depressed and released after
entering the combination. The latch will not retract until the “ENTER”
button is depressed and released.

Caution: Check the operation of the latch by making sure that the
deadlatch (a) stops against the strike (b) as shown and does not slide into
the strike opening when the door is closed. If that situation occurs, then a
total lockout may occur. This will void our warranty of the complete lock
mechanism. If necessary, correct the door over-travel by using the rubber
bumpers as described in Section N (Installing Rubber Bumpers).

COMBINATION SETTING RECORD

Combination & ENTER Date

& ENTER

& ENTER

& ENTER

& ENTER

& ENTER

& ENTER

& ENTER

& ENTER

18

N. INSTALLING RUBBER BUMPERS

N-1 Close the door and apply pressure making sure

the deadlatch (a) rests on the strike plate (b) as
shown. Standing on the frame (door stop) side of
the door, check for gaps between the door and
the frame on the three sides of the frame (left,
right, and top).

N-2 Mark locations where the gaps are approximately

3

⁄16" (5 mm). Make sure these locations are free
from grease and dust. Peel the bumpers (c)
(supplied) from their protective backing without
touching the adhesive surface and stick them on
the marked locations.

Note: Allow 24 hours for adhesive to set before testing.
The door may be operated normally during this time.

O. HOW TO RESET A LOST OR

UNKNOWN COMBINATION

There is no way to determine a forgotten, unknown or lost combination from
the front or outside of the lock. However, it can be reset and recovered or
reset and changed to a new combination by following the steps in this section.

Warning: Since this procedure is of a technical nature, only technically trained
personnel in the lock and hardware field should undertake this operation. For
further assistance, call the Kaba Access Control technical support line at

800-849-TECH (8324) or 336-725-1331 between 8AM and 5PM Eastern
Standard Time, Monday through Friday (except holidays).

O-1 Removing Lock From Door

Remove both the outside unit assembly (a) and the
inside unit assembly (b). (Reverse procedures from
sections E and F of this manual.)

O-2 Removing Combination Chamber Assembly

Carefully remove the base plate of outside unit
assembly (a) by removing the 2 Phillips screws (one screw
may be found under an inspection sticker).

Remove the combination chamber assembly (b) from the
base plate by removing the 2 Phillips screws (c).

Remove the 3-sided dust cover (d) to fully
expose the chamber by removing 2 small
Phillips screws (e). (May be 1 screw (x) in
newer models)

a

b

c

b

a

e

d

(x)

c

a

Correct

Incorrect

a

b

b

19

O-3 Resetting and Recovery of Current Combination

To reset the code gears (a), each one of the 5 “L” shaped
legs (b) of the unlocking slide (c) must engage snugly
with the corresponding code gear pocket (d) next to it.

Position the chamber in one hand, as
shown. Hold chamber by the top screw tab
(e) and bottom screw tab (f).
Rotate the reset cam (g) back toward you
with your finger, towards the key stems (h) as far as it will
go and then release. Now look at the code gears (a) and
the unlocking slide (c). Note that some or all 5 of the code
gear pockets (d) are rotated away from the “L” shaped
legs (b) as if out of alignment. Typically each code gear
pocket will be at a slightly different distance compared to
the other.

Note: Sometimes two different gear pockets are away from alignment by
exactly the same distance – this indicates that the current combination uses
two different number buttons (example, 2 and 4) depressed at the same
time as part of the combination.

Using a small flat blade screw driver or your thumbnail, depress the key
stem which corresponds to the gear pocket which has been rotated the
farthest away (out of alignment) from the “L” shaped leg. When
depressed, the key stem(s) should stay down and the corresponding
gear pocket(s) should move closer to its corresponding “L” leg, closer to
alignment. Record the key stem number. This is the first number of your
combination.

Note: If two gear pockets are at the same distance, depress
both of these corresponding key stems at the same time.

Continue by pressing the key stem that corresponds to the gear pocket
that was the next furthest away (do not include gear pockets that have
already been rotated). Record each key stem number that is depressed.
Continue this procedure until all five gear pockets are aligned with their
corresponding “L” shaped legs on the unlocking slide. The combination
is the recorded numbers, in the order recorded.

Note: If you depress the wrong key stem by mistake, rotate the reset cam
back toward you, (toward the key stems and release). This resets the code
gears and you must repeat the above procedure, O-3.

a

c

j

b

d

i

a

c

f

j

g

h

e

20

O-4 Clearing the Current Combination and Setting a New Combination

Note: Align the code gear pockets with the “L” shaped legs.

Depress the combination change button (i) located on top
of the combination chamber and release.

Rotate the reset cam back toward you with your finger
(toward the key stems) as far as it will go and release.

Enter your new combination by depressing the key stem
corresponding to the first number (1 through 5) of your
combination. For example, if the new combination is 3-2-5,
then you would depress 3 first, then 2 and finally 5. Record
this new combination for future reference.

Push the shoulder (j) at the bottom of the Unlocking slide up toward the
combination change button and release. If each of the 5 “L” shaped legs of
the unlocking slide engages snugly inside its corresponding code gear pocket,
then it confirms that the new combination has been successfully changed.
Rotate the reset cam (g) back toward you and release.

Note: If all 5 “L” shaped legs do not align fully with their corresponding
code gear pockets, repeat the procedures O-3 and O-4.

O-5 Reinstalling chamber assembly into lock and retesting

Reinstall the 3-sided dust cover over the combination chamber with the
2 small Phillips screws removed. (May be 1 screw in newer models)
Reinstall the combination chamber assembly to the base plate with the
2 Phillips screws removed.

Reinstall the base plate on to the outside lock assembly with the 2
Phillips screws removed. Make sure all parts have been reinstalled
correctly.

O-6 Reinstall lock on door by following the procedures in Sections E and F

of this manual.

O-7 Retest new combination with lock on door by entering the new

numbers followed by the “ENTER” button and rotating the outside
lever/knob. The lock should open and the latch should retract.

For technical assistance please call

1.800.849.TECH (8324) or 336.725.1331

i

a

c

f

j

g

h

e

21

P. TROUBLE SHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

1. The outside lever/knob

always retracts the latch

after depressing and

releasing the “ENTER”

button only (without -

combination).

2. The outside lever/knob

always retracts the latch

after depressing and

releasing the “ENTER”

button only (without -

combination).

3. The outside lever/knob

will not go completely

inside the outside lock

assembly.

4. Correct combination is

depressed, but the latch

does not retract.

Lock is in “ZERO”

combination.

Activation cam has

flipped over during

lost combination

procedure

Lever catch is

misaligned.

Failed to depress the

“ENTER” button.

Follow the procedure for

Changing Combinations

(Section M) except omit steps

1 and 2 (do not enter the

existing combination).

Remove outside housing

from base, remove chamber

and flip activation cam back

to correct positon.

Insert release tool through

small hole on the outside

unit assembly (under the

lever/knob). Using the tool,

gently push

lever

catch up

until it clicks. Refer to

Section I or J (Installing and

Removing the Outside

Lever/Knob).

Always depress and release

the “ENTER” button after

depressing the correct

combination.

22

SYMPTOM POSSIBLE CAUSE REMEDY

5. Cannot remove key

from outside lever/knob

— key is stuck.

6. Cannot turn outside

lever/knob when correct

code and “Enter” are

pushed.

7. Passage feature will not

operate when key or

thumbturn is turned.

8. Latch is hard to retract

when correct

combination and

“Enter” are entered.

Key was rotated 180

degrees in wrong

direction during

initial install of

outside lever.

During door

thickness

adjustment, the

wrong length

connecting screws

may have been used.

May not have proper

engagement

between the

tailpiece and

passage actuator.

Possible

misalignment

between the strike

and latch—could be

causing excessive

load pressure on

latch and door.

Rotate key counterclockwise.

Insert release tool through

small hole on the outside

unit assembly (under the

lever/knob). Using the tool,

gently push

lever

catch up

until it clicks. Remove outside

lever/knob. Remove key.

Then follow steps in Section I

or J: Installing and Removing

the Outside Lever/Knob.

See Section C. Use Correct

length screws based on door

thickness.

Check tailpiece length—adjust

or replace as needed. Assure

engagement between

tailpiece and actuator is

correct—See Section D.

See Section L for strike

installation and section N for

installation of Rubber

bumpers. (DO NOT MODIFY

STRIKE OR LATCH.)

23

Notes

Kaba Access Control

2941 Indiana Avenue
Winston-Salem, NC 27105 USA
Tel: [phone] or 336.725.1331
Fax: [phone] or 336.725.3269

www.kabaaccess.com

PKG2842 0609