Assa Abloy Corbin Russwin PED5400 FE User manual

Installation Instructions
WARNING
This product can expose you to
lead which is known to the state of
California to cause cancer and birth
defects or other reproductive harm.
For more information go to www.
P65warnings.ca.gov.
Attention Installer: Improper
installation may result in damage
to the product and void the factory
warranty.
WARNING
PED5400 FE & PED5400 A FE
Surface Vertical Rod Exit Devices
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]

2
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
Screw Chart
DESCRIPTION
TOTAL QTY
SUPPLIED
WHERE USED
#10-24 X 3/4" FLAT HEAD
MACHINE SCREW
4
(4) CHASSIS
CORNER MOUNTING HOLES
#10-24 X 3/4" ROUND HEAD
SOCKET SCREW
2 (2) REAR MOUNTING PLATE
#8-32 X 3/8" TRUSS HEAD
MACHINE SCREW
2 (2) CHASSIS TO MOUNT RAIL
#12-24 X 3/4" SOCKET HEAD
CAP SCREW WITH MORTISE NUT
4
(2) TOP CASE
TOP MOUNTING HOLES
(2) BOTTOM CASE
BOTTOM MOUNTING HOLES
#12-24 X 1" FLAT HEAD
SOCKET SCREW
4
(2) TOP CASE
BOTTOM MOUNTING HOLES
(2) BOTTOM CASE
TOP MOUNTING HOLES
#12-24 X 3/4" FLAT HEAD
MACHINE SCREW
5
(1) TOP CASE SHIM
(4) 659 TOP LATCH STRIKE
RAIL RETAINER BOLT
1
(1) MOUNT RAIL / CARRIER
TO DOOR
1/4"-20 SHOULDER BOLT
1 (1) THRU INSERT

3
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
Screw Chart
DESCRIPTION
TOTAL QTY
SUPPLIED
WHERE USED
1/4" SLEEVE ANCHOR
3 (3) 653 BOTTOM STRIKE
#10-24 X 1-1/2" OVAL HEAD
MACHINE SCREW
4
(2) TOP ROD GUIDE
(2) BOTTOM ROD GUIDE
#8-32 X 5/16" W/ #6 OVAL HEAD
MACHINE SCREW
12
(2) CHASSIS COVER
FRAME SIDE
(2) END CAP
(4) TOP CASE COVER
(4) BOTTOM CASE COVER
#8-32 X 5/8" W/ #6 OVAL HEAD
MACHINE SCREW
2
(2) CHASSIS COVER
RAIL SIDE
1/4"-20 X 2-3/8" KNURLED FLAT HEAD
MACHINE SCREW
2
(2) EXIT TRIM
(IF USED)

4
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
Rail Cutting Guide (Provided)
Support Block (Provided)
Tools Needed
Before installation:
1. Install mullion, if used.
2. Fit and hang door.
3. Check the box’s label for the size of the exit device.
The surface of the door where the exit device is to be applied
must be flush. Clear away any raised projections to allow
exit device to rest on the flat surface of the door. If shim kit is
required, contact your distributor.
Note: Please refer to trim and
other installation instructions
provided in the box.
INSIDE
LEFT HAND
REVERSE
BEVEL
RIGHT HAND
REVERSE
BEVEL
THIS EXIT DEVICE IS HANDED
CHECK HAND OF DEVICE AGAINST APPLICATION
OUTSIDE
Handing
To Change Hand of a PED5401 Exit Device:
1. Remove both chassis pins and main slide.
2. Remove lift lever pin and lift lever.
3. Rotate chassis 180° and reposition lift lever and lift lever pin as shown below
4. Position main slide with large end of main slide at the bottom and retain with chassis pins.
Lift lever pin
Chassis pin
Lift lever
Main slide
Large end
Chassis
Left Hand
Reverse
Right Hand
Reverse
Main Slide
Large end
Lift lever

5
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
Product Overview
End Cap
Mounting Plate
Push Rail Assembly
"Lock Down Key"
To operate: Depress push rail; Insert hex
key, and turn counter clockwise. Not
avaliable for fire rated devices.
Chassis Cover
Bottom rod guide
Bottom rod
Bottom case
Bottom case cover
Shim
Shim
Shim
Shim
Interlock Shim
Top case
Top case cover
Top rod guide
Top rod
Shim
Rail shim
Top strike
Bottom strike
Rail retainer bolt
Insert retainer bolt
Chassis

6
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
A
12
• With door closed, tape template for
chassis / trim on inside of door, along vertical
and horizontal reference lines.
• Fold top case / top strike template and tape
on inside of door along vertical reference
lines.
• With door closed, measure and mark 2-3/4"
to locate the vertical reference center line of
the chassis, top case, and bottom case.
• Horizontal reference line is rail centerline
height. Standard rail centerline height is 39-
5/8" above the finished floor.

7
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
3
NOTE: Any holes drilled from the outside need
pilot holes drilled from the inside to ensure good
alignment.
NOTE: For electrical trim applications, ensure
access to a raceway from the trim to the electric
hinge or armored door loop.
2X
3
8
"
THRU BOTH SIDES
2X #12-24
TAPPED HOLES
THIS SIDE ONLY
• Spot and drill all holes from inside of door.
• If needed, prepare pockets for outside
trim. See installation instructions supplied
with trim for details.

8
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
4
1 3
4
"
13
16
" 1
2
"
(4) #12-24
TAPPED HOLES
3
16
"
1 1
8
"
1 5
16
"
ALIGN WITH
C
L
OF VERTICAL
ROD EXIT DEVICE
DOOR
STOP
Frame Cutout
RECOMMENDED CUT-OUT IN FRAME FOR 659 TOP BOLT/STRIKE.
THIS CUT OUT IS LARGE ENOUGH FOR FUTURE ADJUSTMENT.
• Transfer vertical centerline to door frame.
Prepare rectangular cut-out in frame for top
strike.
• Insert top strike. With door closed, align the
interlocking shim with the top strike and
place on the vertical reference line. Mark and
drill four mounting holes using 11/64" drill
and #12-24 tap.

9
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
5
6
Mount top strike, (4) #12-24 x 3/4" phillips flat head machine screws. Flat side of top bolt should be facing
away from the door.
Note: All four fasteners required. DO NOT TIGHTEN FULLY.
• Attach top case and interlocking shim using (2) sex nuts from the outside door
surface with (2) #12-24 x 3/4 socket head cap screws from inside in the two
top holes and (2) #12-24 x 3/4 flat head socket head screws in two bottom
hole (1/8" Allen wrench).
• With the top chassis and interlocking shim secured, the top strike should
engage the top case and interlocking shim when the door is closed (A).
• Trace the outline of the interlocking shim (B).
A
B

10
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
7
8
Remove the top case to expose the center hole on the Interlocking shim. Ensure the interlocking shim is
aligned with the tracing from Step 6.
Mark and tap center hole with #12-24 thread.

11
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
9
10
Attach interlocking shim with (1) #12-24 x 3/4" flat head socket head screw.
• Reinstall top case.
• Check for top case and top strike engagement.
• Tighten all screws.

12
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
11
• Secure chassis and shim to door
with (4) #10 flat head screws, using
corner mounting holes.
• If trim is used, refer to step 11a.
Position ET trim on door. Align spindle with bell
housing. Thru-bolt chassis to ET trim with (2) 1/4-20
flat head screws.
11a 800PT and 900PT Series ET Trim
Chassis
PT Series Trim
12
Refer to rail size listed on the box the device was
shipped in. Break rail shim to the length that
corresponds to the rail size.
Note: If shim needs to be cut, always cut shim from
the end closest to the hinge edge.
Use breaking lines to shorten
shim to the needed rail size.

13
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
If the rail doesn’t need to be cut, continue to page 15, step 13.
If the rail must be cut, follow these steps on page 13 and 14:
Refer to the individual exit device installation instructions for rail cutting requirements / restrictions.
Instructions will vary based on device type and options.
Do not cut closer than 1-5/8" from
the the front edge of the rail insert.
• Determine cut off dimension “X” by subtracting 2-7/8"
from dimension “Y”. Mark cut off point on mounting
rail. (See below.)
Vertical reference line (C of chassis)
L
2-7/8"
min.
For doors with stile rail, the stile must overlap by 5/16"min.
X
Y
A. Ensure there isn’t a gap between the insert
and the dogging slope, and the carrier is
flush with the mount.
B. Mark rail at the required cut length.
Insert
Dogging
slope Cut line
Mount
Carrier
Information for Cutting Rails
Rail Sizes Door Widths
Standard
36"
42"
48"
W042
W048
W036 (Std.)
Rail cutting guide

14
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
F. Using a hack saw with a new blade or a chop
saw with a metal cutting blade, cut the rail,
ensuring that the blade stays pressed against
the rail cutting guide.
G. Deburr and smooth all cut edges with a file.
D. Wrap the rail and insert in masking tape, as
shown.
E. Place the rail cutting guide over the masking tape and align it with the cut line. Clamp the cut guide to the rail
using a C-clamp.
C. Ensure plastic insert support is installed under the
cut line.
Cut line
Rail Cutting Guide
Rail cutting guide, continued.
Cut
line

15
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
13
Level rail shim on the door and use it as a template. Mark the slot centerlines shown and punch locations for
threaded holes where the centerlines intersect.

16
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
15
14
Remove rail shim from door to expose tracing.
Drill and tap (2) holes as shown in door surface.
(“I” drill with 5/16-24 tap for hole at the middle of
the door, #7 drill with 1/4-20 tap for hole closer to
hinge.
Install rail retainer bolt (3/16" wrench).
Tracing from
Step 13

17
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
16
19
Ensure mounting rail bracket is against
the rail without a gap.
Depress chassis lift arm, and slide rail assemby with
rail shim onto chassis. Ensure rail retainer bolt engages
properly with slot in rail shim and rail assembly.
17
Install rail insert / shoulder bolt sub-assembly.
Do not fully tighten shoulder bolt.
18
Insert the end cap bracket into the rail assembly
with shim.

18
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
20
Verify the rail is level and mark mounting holes,
using the bracket as a guide.
21
Drill and tap end cap bracket holes #10-24
(2 Places).
22
Install end cap bracket using round head socket cap
#10-24 x 3/4" screws, supplied. Tighten the insert
shoulder bolt.
23
Attach rail assembly to chassis with (2) #8 truss
head machine screws.

19
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
PED5400 FE & PED5400 A FE Series
24 • Transfer vertical centerline to threshold.
• Align bottom strike.
• Mark and drill holes 1-5/8" to 1-3/4" deep for (3) 1/4" sleeve anchors.
Note: No clearance in floor is required.
25 • Disassemble anchors and drop lower
portion into the hole with threads facing
towards the top of the hole.
• Align holes in strike with holes in floor.
• Screw the top half of the anchor onto
the installed piece through the holes in
the strike. Tighten the anchors.
Ensure stop is
against the door.

20
PED5400 FE & PED5400 A FE Series
Installation Instructions
Surface Vertical Rod Exit Device
FM612 01/23
Copyright © 2023, ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in
part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited. Patent
pending and/or patent www.assaabloydss.com/patents.
1-800-543-3658 • [e-mail]
26 Using the verical reference line, with the bottom case as a template, align
bottom case as shown. Mark (4) mounting hole locations.
5
8
"
3
16
"
5
16
"
27 • Drill and tap top mounting holes for (2) #12-24 x 3/4" flat head socket
screws, using 11/64" drill and #12-24 tap.
• Use 3/8" drill bit to drill two bottom mounting holes through door.
2X #12-24
TAPPED HOLES
THIS SIDE ONLY
3
8
"
THRU BOTH SIDES