E-PLEX 1 MORTISE INSTALLATION INSTRUCTIONS

E-PLEX 1 MORTISE INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS Tools Required.................................................................3 Exploded Instll Prts...........................................................4 Hnding Digrm...............................................................5 A. Mortise Hnding............................................................5 B. Door Preprtion...........................................................6 C. Instlling the Strike.........................................................7 D. Instlling Outside Unit Assembly.............................................8 E. Instlling Inside Unit Assembly...............................................9 F. Instlling the Inside Lever...................................................9 G. Chnging Key-In-Lever Cylinder..............................................10 H. Instlling / Removing Outside Lever (Key-In-Lever) KIL..........................11 I. Instlling / Removing Outside Lever (Interchngeble/..........................11 removble core models) J. Instlling the Bttery Pck nd Cover.........................................13 K. Testing the Opertion of the Lock............................................14 L. Progrmming nd Softwre Settings.........................................14 M. Instlling Rubber Bumpers..................................................15 Wrning The Mster Code of this lock hs been fctory preset: 1,2,3,4,5,6,7,8. To ctivte lock functions, the mster combintion must be chnged t time of instlltion. Wrnings nd Cutions Importnt: Crefully inspect windows, door frme, door, lights, etc. to ensure tht the recommended procedures will not cuse dmge. Kb Access Control s wrrnty does not cover dmges cused by instlltion. Cution: Wer sfety glsses when prepring door. 2

Introduction The purpose of this mnul is to instruct the instller on the proper instlltion procedure for the E-Plex 5x63, 5x64, 5x68 nd 5x69 1" Americn Steel Mortise (ASM) Mortise locks. These instructions pertin to models with nd without dedbolts. For models without dedbolts, plese disregrd ny references to thumbturn in the instructions. OPERATIONAL NOTE: The E-Plex Mortise lock is lmost identicl to the E-Plex 5000 Cylindricl lock with the following exceptions: 1. Opertion of the Lever When the lock s hnding is properly set, only downwrd rottion of lever will ctute ltch. 2. Key Override Use The key override differs in tht rotting the key does not ctute the ltch. To use the key override the key must be inserted into the cylinder nd rotted counter clockwise until it stops (pproximtely 90 degrees) then while holding the key in this position with one hnd use the other hnd to rotte the lever downwrd to retrct the ltch. Once the lever hs rotted few degrees the key my be relesed. TOOLS REQUIRED Sfety glsses 1 2" (13 mm) chisel 1 8" (3 mm) drill bit 1 4" (7 mm) drill bit 1 2" (13 mm) drill bit 2 1 8" (54 mm) hole sw Drill Awl or center punch Hmmer Smll flt screwdriver Phillips screwdriver (#2) Fine steel file Mortising mchine Router Mortise fceplte router templte Adjustble squre Tpe mesure Pencil Tpe Clening supplies (drop cloth, vcuum) 3

E-PLEX 1" Mortise Lock 5x63, 5x64, 5x68 nd 5x69 Bttery Pck Cover Bttery Pck Bttery Cover Screws Security Screw Tool Inside Unit Assembly Lectrobolt Allen Wrench Outside Unit Assembly Mounting Plte Screws Thumbturn Spindle Upper Mounting Screw Inside Lever Lower Mounting Screws Relese Tool Strike Mortise Spindle Mounting Plte Outside Lever Assembly Mortise Lock Mortise Fceplte INSTALLATION QUALIFICATIONS These instructions re designed for use by mintennce professionls or lock instllers who re fmilir with common sfety prctices nd competent to perform the steps described. Kb Access Control is not responsible for dmge, injury or mlfunction due to incorrect instlltion. 4 For technicl ssistnce plese cll 1-800-849-TECH (8324) or 336-725-1331

Hnding Digrm To determine hnding, fce the door from the exterior (ccess) side nd select the corresponding digrm below. LH RH LHR RHR Chrt Model Number Hnding Dedbolt E5x63 E5x68 LH/RHR LH/RHR E5x64 E5x69 RH/LHR RH/LHR No Yes A. MORTISE HANDING The 1" Mortise is not field reversible. You must hve the pproprite model for the door hnding of the instlltion. For LH (left hnd) nd RHR (right hnd reverse) For RH (right hnd) nd LHR (left hnd reverse) 5

B. DOOR PREPARATION If using the instlltion jig to prepre the door, refer to the instructions provided with the jig, then proceed with step 7. B-1 Mrk the hndle height on the edge of the door, s determined directly from the strike. ( C L ) Door Lever Centerline= Bottom Edge of Strike lip 1 1 4" The xis of rottion of the hndle is level with the bottom lip of the strike. B-2 Align the templte long the verticl center line of the mortise (CL) t the desired hndle height, nd tpe it to the door. Mortise B-3 Mrk ll holes nd cutouts for the mortise in the edge of the door nd remove the templte. B-4 Locte the two sets of verticl fold lines on the templte llowing you to djust the positioning of the templte depending on the bevel of the door. Note: Fold lines on templte re for 1 3 8" door. Some thickness nd bevel conditions my mke it necessry to re-position the templte for mrking ech side of the door. B-5 If the door hs no bevel, fold the templte long the solid lines. Align RH/LHR (ASM shown) LH/RHR the fold with the edge of the door nd mrk the holes for the lock. Repet on the other side of the door. If the door hs 3 bevel, fold nd lign the dshed line mrked H on the templte with the higher-beveled edge of the door nd mrk the lock holes on tht side of the door. Repet on the side with the lower-beveled edge using the dshed line mrked L. 6

B-6 Prepre the cutout for the mortise in the edge of the door using mortising mchine, router nd chisel (for dimensions, refer to templte). Ensure clernce is provided for moving ltch prts s indicted on the templte. B-7 When mking holes, drill from both sides of the door to prevent unsightly dmge (for dimensions, refer to templte). Drill the smll holes before the lrge holes. This will keep smll holes on loction before the 2 1 8" holes re mde tngent with them. B-8 Check the bevel of the mortise fceplte. If djustment is R Q required, loosen the two bevel P screws (R) nd djust mortise front plte ngle to mtch the bevel of the door. Logo B-9 Re-tighten screws. B-10 Instll the mortise with two 1" Phillips screws (Q) provided. R B-11 Instll mortise fceplte (P) with the two 8-32 x 1 4" screws provided. C. INSTALLING THE STRIKE C-1 Align the pper templte on the door frme to mtch with the desired hndle height, nd long the verticl center line of the mortise (CL), which is lso the center line of the door, llowing for ny bumpers on the door frme. ( C L ) Respect pplicble building codes regrding hndle height. C-2 Select the strike for the desired hnding, ccording to the depiction on the templte. Mrk the loction of the strike cutout nd mounting screws. Strike Cutout 7

C-3 Drill pilot holes for the strike mounting screws. Mortise the door frme for the strike dimensions shown. 3 3 8" (L) X 1" (D) X 1" (W) 3 3 8 Note: Mke certin not to mortise over screw holes drilled erlier. C-4 Position the strike ginst the door frme nd lign it with the mounting screw holes. Then mrk the outline of the strike. C-5 Remove ny mteril from within the strike outline () so tht the strike will be flush with the door frme. C-6 Instll the strike using the screws provided. D. INSTALLING OUTSIDE UNIT ASSEMBLY Note: Ensure tht the mounting hole for the red collrs is clened out so tht the collrs re not F crushed upon instlltion. If necessry, the hole cn be opened up to 5 16". D-1 For door thickness of 1 3 8", insert the squre G spindle (G) into the outside housing hub. D-2 If your lock comes with thumbturn, insert the end (with the ring groove) of the thumbturn spindle (F) into the smll spindle hole in the outside housing. D-3 Plce the outside housing on the door so tht the bottom spindle engges the hub on the mortise, nd the top thumbturn spindle psses through the mortise top hub. The outside unit ssembly (c) will rest flush ginst the door. Ensure the red collr is seted into the top left mounting hole. 8

E. INSTALLING INSIDE UNIT ASSEMBLY E-1 Plce inside mounting plte flush ginst the door s shown. For door thicknesses of 1 3 8" insert digonlly (s shown) two 1 1 2" Phillips flt hed screws (supplied in prts door kit). Note: The screws must correspond to the two through holes in the mortise. E-2 Insert the squre spindle (G) into the inside housing hub. E-3 Put the thumbturn (T), if pplicble in verticl position nd plce the inside trim ssembly on the door so tht the upper spindle (F) engges the thumbturn nd mortise hubs, respectively. Ensure the red collr is seted into its mounting hole. Crefully push the inside housing flush ginst the door. E-4 Supplied hrdwre should correspond to the chrt below: Door LectroBolt Top Mounting Lower Thickness Size Screw Size Mounting Screws 1 3 8" 2 3 8" 2 1 2" 5 8" (35 mm) (60 mm) (64 mm) (16 mm) E-5 Insert the LectroBolt through the red inside Lectrobolt housing hole mrked with the lightening bolt symbol. For now, only prtilly tighten the LectroBolt to keep the red collrs in position. E-6 Then, insert nd tighten the other three mounting screws. (Refer to the chrt for correct screw lengths.) E-7 Finish tightening the LectroBolt to secure the lock on the door. Wrning: If using power drill, plese be creful not to over-tighten s this could cuse dmge to the mounting screws nd threds. C Red Collr F G T 5 8" (16mm) F. INSTALLING THE INSIDE LEVER Insert the inside lever (A) onto the inside unit ssembly. Secure the inside lever with the hex screw (B) (supplied) using the llen wrench (C) (supplied). c b 9

KABA E-PLEX 5x00 SERIES LIMITED WARRANTY Kb Access Control wrrnts this product to be free from defects in mteril nd workmnship under norml use nd service for period of three (3) yers. Kb Access Control will repir or replce, t our discretion, 5000 Series Locks found by Kb Access Control nlysis to be defective during this period. Our only libility, whether in tort or in contrct, under this wrrnty is to repir or replce products tht re returned to Kb Access Control within the three (3) yer wrrnty period. This wrrnty is in lieu of nd not in ddition to ny other wrrnty or condition, express or implied, including without limittion merchntbility, fitness for purpose or bsence of ltent defects. ATTENTION: This wrrnty does not cover problems rising out of improper instlltion, neglect or misuse. All wrrnties implied or written will be null nd void if the lock is not instlled properly nd /or if ny supplied component prt is substituted with foreign prt. If the lock is used with wll bumper, the wrrnty is null nd void. If doorstop is required, we recommend the use of floor secured stop. The environment nd conditions of use determine the life of finishes on Kb Access Control products. Finishes on Kb Access Control products re subject to chnge due to wer nd environmentl corrosion. Kb Access Control cnnot be held responsible for the deteriortion of finishes. Authoriztion to Return Goods Returned merchndise will not be ccepted without prior pprovl. Approvls nd Returned Goods Authoriztion Numbers (RGA Numbers) for the 5000 Series re vilble through our Customer Service deprtment in Winston-Slem, NC (800) 849-8324. The seril number of lock is required to obtin this RGA Number. The issunce of n RGA does not imply tht credit or replcement will be issued. The RGA number must be included on the ddress lbel when mteril is returned to the fctory. All component prts including ltches nd strikes (even if not inopertive) must be included in the pckge with return. All merchndise must be returned prepid nd properly pckged to the ddress indicted. * Simplex 5000 locks re wrrnted three (3) yers from dte of purchse. E-Plex 5x00 locks re wrrnted three (3) yers from dte of ctivtion.

BUSINESS REPLY MAIL FIRST-CLASS MAIL PERMIT NO. 1563 WINSTON-SALEM, NC POSTAGE WILL BE PAID BY ADDRESSEE KABA ACCESS CONTROL 2941 INDIANA AVENUE WINSTON-SALEM, NC 27199-3770 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES

REGISTRATION CARD Thnk you for purchsing our product. In order to protect your investment nd to enble us to better serve you in the future, plese fill out this registrtion crd nd return it to Kb Access Control, or register online t www.kbccess.com. Nme Position Compny Address City Stte ZIP (Postl Code) Country Phone Emil Nme of Deler Purchsed From Dte of Purchse Lock Model Number This lock will be used in wht type of fcility? o Commercil Building o Industril / Mnufcturing o Airport o College/University o Government/Militry o School/Eductionl o Hospitl/Helthcre o Other (plese specify) Wht re is being secured with this lock? (e.g. Front Door, Common Door, Exercise Room) This lock is: o New Instlltion o Replcing conventionl keyed lock o Replcing Kb Mechnicl Pushbutton Lock o Replcing Kb Electronic Access Control o Replcing Keyless Lock other thn Kb How did you lern bout Kb Access Control Pushbutton Locks? o Advertisement o Previous Use o Internet / Web o Another Use o Locksmith o Mintennce o Trining Clss o Other (plese specify) Wht ws your reson for buying this lock? Who instlled your lock? o Locksmith o Mintennce o Other o Check here if you would like more informtion on Kb Access Control locks.

Notes

G. CHANGING KEY-IN-LEVER CYLINDER On key-in-lever models of the E-Plex 5000 series, the outside lever comes pressembled with Kb s key-in-lever cylinder (Kb 1599). To use different key-in-lever cylinder follow remining steps in this section. b G-1 To remove KIL (key-in-lever) cylinder () from the c outside lever (b). Remove the cylinder insert (e) d nd the cylinder retiner (c) using smll flt blded screwdriver or smll needle nose pliers. e G-2 Determine the proper tilpiece (d) from the f chrt below for your KIL cylinder. You must use Kb tilpiece. The K 2 tilpiece is pressembled with the Kb 1599. K1 K2 TAILPIECE KIL CYLINDER Abloy 5277, Abloy 5477, Ass 65691, Kb 1539, Kb Gemini 4730 Ass 65611, Austrlin: Kb expert 107K5 & Boyd KC286, Corbin-Russwin 2000-03, Kb 1599, Schlge 23-001, Schlge Primus 20-760, Kb Peks 1099 K3 Medeco 20W200H1 K4 Arrow C100, Srgent 10 LINE K5 Mrks G-3 Assemble the required tilpiece (d) (from bove) c with your KIL cylinder. All tilpieces must be d instlled verticlly (with key removed from cylinder) for proper instlltion. e G-4 Insert the KIL cylinder () into the outside lever nd secure it with the cylinder retiner (c) nd the cylinder insert (e) until the KIL cylinder is snug nd unble to move freely. b 10

H. INSTALLING / REMOVING OUTSIDE LEVER (Key-In-Lever models only) c H-1 Mke certin the lever ctch is up s shown (c). To successfully instll the outside lever, the lever sleeve (f) tb must be positioned correctly with the respective notch on the lever. The lock comes shipped with the lever sleeve lredy instlled in the lock housing. When f instlling lever, ensure it is oriented to engge the lever sleeve to ccommodte desired lock hnding s shown. H-2 Insert one of the supplied keys () into the outside lever (b) nd rotte key counterclockwise 45 degrees. H-3 Insert the outside lever (b) until it is flush to the outside unit ssembly (g). Secure the outside lever by rotting the key () clockwise 45 degrees to horizontl position. Remove key. Note: To remove the outside lever from the outside unit ssembly, follow the step below. H-4 Insert one of the supplied keys () into the outside lever nd rotte it counterclockwise 45 degrees. Insert relese tool (d) into the smll hole (e) under lever s shown. Gently push lever ctch up until it clicks. Remove tool, then remove outside lever (b). I. INSTALLING / REMOVING OUTSIDE LEVER (Interchngeble / Removble Core Models) I-1 Mke certin the lever ctch is up s shown (c). c To successfully instll the outside lever, the lever sleeve (f) tb must be positioned correctly with the respective notch on the lever. The lock comes shipped with the lever sleeve lredy instlled in the lock housing. When instlling lever, ensure it is oriented to engge the lever sleeve to ccommodte desired lock hnding s shown. f Note: For ll interchngeble/removble cylinders except ASSA/Medeco/Yle, proceed to section I-2. For ASSA/Medeco/Yle cylinders, skip to section I-5. Correct Position 45º b KIL Lever Sleeve LH RH 45º e Correct Position b Incorrect Position d IC Lever Sleeve LH RH g g Incorrect Position 11

I-2 Insert the outside lever () until it is flush to the outside unit ssembly (b). To secure the outside lever, insert the relese tool (d) (or screwdriver) into the outside lever s shown, nd slide the lever ctch down until it clicks. Mke certin lever is ttched before instlling the core. I-3 Insert the supplied tilpiece (e) verticlly into the outside lever s shown. Mke certin tht you rotte the tilpiece so tht it will lign with the interchngeble core. For screw cp type cylinders (Schlge) (g), the tilpiece must be ssembled to the cylinder first s shown (verticl position). Insert the interchngeble core into the outside lever. Note: To remove the outside lever from the outside unit ssembly, follow steps below. I-4 Remove the interchngeble core (g). Then remove the tilpiece (e). I-5 For ASSA/Medeco/Yle interchngeble/removble cylinders, the tilpiece must be prepped for the desired length before instlltion. When using Yle cylinder on cylindricl ltch ppliction, mesure the door thickness of the intended ppliction. I-6 Notice the score mrks on the flt portion of the ASSA/Medeco/Yle tilpiece. Using the digrm to the right, locte the score mrk on your tilpiece tht mtches your cylinder prep for the intended ppliction, nd brek the tilpiece off ccordingly. I-7 Using 2 pirs of pliers, brek the tilpiece to the desired length of the intended ppliction by holding 1 pir of pliers on the good side of the score mrk nd one pir on the other side of the score mrk. Slowly move the 2nd pir of pliers up nd down until the unneeded portion of the tilpiece breks free. verticl I-8 Insert the Medeco tilpiece (e) verticlly into the outside lever s shown. Mke certin tht you rotte the tilpiece slightly so tht it will lign with the interchngeble/removble cylinder. Insert the interchngeble/removble cylinder into the outside lever. Note: To remove the outside lever from the outside unit ssembly, follow steps below. d b e b MEDECO 5 PIN, EXIT & MORTISE g b f YALE 6 & 7 PIN, EXIT & MORTISE ASSA & MEDECO 6 PIN, EXIT & MORTISE YALE 6 & 7 PIN, CYLINDRICAL THIN DOOR (1 3 8" (35 mm) to 1 1 2" (38 mm)) (DO NOT SHORTEN TAILPIECE - For 1 5 8" (41 mm) to 2 1 4" (57 mm)) ASSA/MEDECO 5, 6 & 7 PIN, CYLINDRICAL DO NOT SHORTEN TAILPIECE d 12

I-9 Remove the interchngeble/removble cylinder. Then remove the tilpiece (e). Note: You my wnt to use needle nose pliers for some tilpieces. I-10 Insert the lever relese tool (d) into the smll hole (f) under lever s shown. Gently push lever ctch up until it clicks. Remove tool, then remove outside lever (). Note: You my wnt to use needle nose pliers for some tilpieces. Insert the relese tool (d) into the smll hole (f) under the lever s shown. Gently push lever ctch up until it clicks. Remove tool, then remove the outside lever (). Note: Do not shut door until instlling btteries nd testing opertion s outlined in the following two sections. J. INSTALLING THE BATTERY PACK AND COVER/CHANGING BATTERIES J-1 To instll the bttery pck (f) nd cover (g), snp the cble connector f onto the top of the loded bttery g pck. Then plce the bttery pck h into the cover, terminls t the top. Put the two security screws (h) into the cover nd fsten the cover to the inside housing with the security screw tool (i). i Cution: Over-tightening these screws could strip the threds in the housing or crck the cover. Wrning: If the lock goes without power for more thn two minutes, you will lose the lock s current dte nd time only. If this hppens, progrm the lock with the correct dte nd time. Refer to Opertions Mnul. J-2 Remove the two screws (h) securing the bttery cover to the housing, using the security screw tool (i) provided with your lock. J-3 Remove the four depleted btteries nd instll four new Alkline only AA btteries. Ensure tht ech bttery is instlled in the proper direction s shown t ech bttery loction in the bttery holder (f). Wrning: Do not instll 9V bttery. Your lock opertes on 4 lkline only AA btteries (6V). A 9V will ruin the electronics in the lock, nd void your wrrnty! 13

J-4 Reconnect the bttery cble. Plce the bttery holder into the cover. Screw the bck cover onto the inside housing, ensuring tht the cble is not trpped under the edge of the cover. Cution: Over-tightening these screws could strip the threds in the housing or crck the cover. K. TESTING THE OPERATION OF THE LOCK K-1 Rotte inside lever nd hold. Ensure tht the mortise ltch is fully retrcted nd flush with the mortise fceplte. Relese the inside lever; the ltch should be fully extended. K-2 Enter the fctory-set combintion: 1,2,3,4,5,6,7,8. You should see green light nd her high-pitched tone s you push ech button. When the lock opens you will briefly her the sound of n electric motor. If 1,2,3,4,5,6,7,8 does not seem to work, plese follow the steps to perform hrd reset by following the procedure in section L. K-3 Rotte outside lever nd hold. Ensure tht the ltch is fully retrcted nd flush with the ltch fceplte. Relese the outside lever; the ltch should be fully extended. When the lock re-locks, you will gin her the motor. K-4 Insert key into the outside lever. Rotte key counterclockwise to stop position nd hold. Ensure tht the ltch is fully retrcted nd flush with the ltch fceplte. Rotte the key clockwise to the horizontl position nd remove the key. The ltch should be fully extended. K-5 To test the dedbolt function (where pplicble), turn the thumbturn knob to extend the dedbolt. A red light should flsh once. Then, turn the thumbturn gin nd verify tht the dedbolt is retrcted nd there is flsh of the green light. Note: Refer to the Operting Mnul to set up lock opertion. L. PROGRAMMING AND SOFTWARE SETTINGS: L-1 You must chnge the mster Code from the fctory defult to nother code to progrm the lock. For further informtion on how to mnully progrm the E-Plex 3x00/5x00 Series Models, refer to the compnion E-Plex 3x00/5x00 Opertion Mnul. Softwre is required to progrm the E3200/E5200 Series Locks. L-2 When configuring the E3000/E5000 Series Locks using the optionl Stndrd Softwre, choose the box tht contins Entry Lock with Pssge (Cylindricl or Mortise without Dedbolt) during lock setup. L-3 When configuring the E3200/3700 nd E5200/E5700 Series Locks using the Enterprise Softwre, select the pproprite lock type during lock setup.. 14

M. INSTALLING RUBBER BUMPERS M-1 Close the door nd pply pressure mking sure the dedltch () rests on the strike plte (b) s shown. Stnding on the frme (door step) side of the door, check for gps between the door nd the frme on the three sides of the frme (left, right nd top). Correct b M-2 Mrk loctions where the gps re pproximtely 3 16" (5 mm). Mke sure these loctions re free from grese nd dust. Peel the bumpers (c) (supplied) from their protective bcking without touching the dhesive surfce nd stick them on the mrked loctions. Note: Allow 24 hours for bumper dhesive to set before testing. The door my be operted mnully during this time. Incorrect b c 15

Kb Access Control 2941 Indin Avenue Winston-Slem, NC 27105 USA Tel: (800) 849-8324 (336) 725-1331 Fx: (800) 346-9640 (336) 725-3269 www.kbccess.com PKG3140 0912