ilco 79M Series User manual

INSTALLATION GUIDE
79 Series Multi-housing Lock
ASM, ESM, ASM Auto Deadbolt Mortises &
Cylindrical Models 23 / 8" and 23 / 4" Backset
PK3561
79 Series Multi-housing Lock

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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1. IntroductionandDisclaimers ...................................................2
2. Checklist and Exploded Views
2.1. PartsandToolsList..........................................................3
2.2. ASM/ESM79MStandardMode ................................................4
2.3. ASM/ESM79TToggleMode ...................................................5
2.4. Autodeadbolt; ASM Inside Trim Assembly 79T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6. Inside Trim Assembly for 79T Toggle Mode Cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Installation of Standard ASM or ESM Models
3.1. ChecktheMortiseHanding....................................................7
3.2. InstalltheStrike .............................................................8
3.3. InstalltheMortise ...........................................................9
3.4. Install the Outside Housing & Inside Trim Assembly without key override . . . . . . . . . . . . . . . 10
3.5. ReversingtheOutsideLever ..................................................11
4 LockTesting................................................................12
5. LockProgramming...........................................................13
6. InstallingtheMechanicalOverride..............................................15
Appendices
A. Mortise Models
A.1. ReversingtheMortiseHanding ................................................23
A.1.1.ReversibleASM.......................................................24
A.1.2.ReversibleESM .......................................................26
A.2. Additional Steps for Autodeadbolt ASM for 79M Standard Mode only . . . . . . . . . . . . . . . . . 28
A.3. Additional Steps for ASM Office for 79M Standard Mode only . . . . . . . . . . . . . . . . . . . . . . . . 29
A.4. Additional Steps for ASM/ESM Storeroom for 79M Standard Mode only . . . . . . . . . . . . . . . 29
B. Cylindrical Models
B.1. InstallingCylindricalModels ..................................................30
B.1. Install the Strike. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
B.2.InstalltheLatch.........................................................30
B.3.InstalltheCylindricalUnit.................................................31
B.4.InsideTrimAssembly....................................................32
B.5. Install Outside Housing & Trim Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Note: This installation Guide is for the 79 Series Multi-housing lock. Images of the lock may be different than your
model. See photo on front cover.
©2009 Kaba Lodging Systems. All trademarks and registered trademarks are the property of their respective owners.
Table of Contents

1 • Introduction and Disclaimers
PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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Target Audience
These instructions are designed for use by maintenance professionals or lock installers who are familiar with common safety practices
and competent to perform the steps described. Kaba Lodging Systems is not responsible for damage or malfunction due to incorrect
installation however arising.
Definition of Terms
In these instructions, the term ASM refers to American Standard Mortise, ESM refers to European Slim Mortise, and ADB refers to
Autodeadbolt Mortise.
Technical Assistance
For technical assistance, call: 1 800 906-4526 / [phone]
Warnings and Cautions
Door Door Frame
Mortise
Max. 3/16"
Please read and follow all directions carefully.
Important: Carefully inspect windows, doorframe, door,
etc. to ensure that the recommended procedures will not
cause damage. Kaba Lodging Systems standard warranty
does not cover damages caused by installation.
Important: The gap between the mortise front plate and
the strike must not exceed 3/16"
Caution: Wear safety glasses when making the holes.
!
!
!
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PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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2 • Checklist and Exploded Views
2.1 Parts and Tools List
Each lockset includes:
(A) Ouside lever handle
(or)
Parts for Mechanical override model only:
(A1) Outside lever handle
(B1) Outside housing 79M Standard mode or B3 for 79T Toggle mode
(C1) Cylinder plug
(D1) Cylinder (79M Series with cylinders keyed different only)
(E1) Cylinder cap
(E2) Instruction sheet “How to attach lever on lock"
(B) Outside housing 79M Standard mode
(B2) Outside housing 79T Toggle mode
(C) Battery holder with 3 AA batteries
(D) Mortise (ASM only shipped assembled with faceplate and 2 x 8-32 x 1 /4" screws)
(or)
Parts for cylindrical models (see illustrations in appendix B):
- cylindrical latch (see B3 page 31)
- cylindrical unit assembled with one pair of screws & 3 spacers
- four (4) other pairs of screws & 3 spacers in hardware bag
- additional extension spring
(E) Inside trim assembly, details depend on lock model (see 2.2, 2.3, 2.4, 2.5, 2.6, A2, A3, A4)
(E2) Inside Trim assembly for 79T Toggle mode (see 2.4 & 2.6 at page 6)
(N) Outdoor gasket to be ordered. ESSENTIAL FOR OUTDOOR INSTALLATIONS
(N1)Tension Spring
Parts inside hardware bag:
(F) Thumbturn (hex) spindle
(G) Square spindle
(H) Torx-head screw
(I) 3 x mounting screws (10-24, 1/8 Hex Head) or (12-24, 1/8" Hex Head for recent models only)
(J) 2 Machined screws (12-24X 1/2" Philips) & 2 wood screws (#12 X 1" Philips)
(K) Strike kit (screws, strike and ASM or Cylindrical dustbox)
(L) 1 extension spring
(M) Parts required to control thumbturn motion
(Q1) 4 pairs of Flat Head Screws 10-24 (for cylindrical only)
(R1) 3 Spacers (for cylindrical only)
(R2) 1 Cylinder with 2 keys for locks with override and cylinders keyed different only
(S) 3 spacers (see page 28) for recent Models only
Tools Required:
Safety glasses
1/2" (13mm) chisel
1/8" (3mm) drill bit
1/4" (6.5mm) drill bit (ESM only)
1/2" (13mm) drill bit
7/8" (22mm) drill bit or hole saw
Drill
Awl or center punch
3/4 (19mm) drill bit
2 1/8" (54mm) hole saw
(Cylindrical Only)
Hammer Rubber mallet
Small flat screwdriver
Torx screwdriver (T-15)
Phillips screwdriver (#2)
Fine steel file
Mortising machine
Router
Mortise faceplate router template
Adjustable square
Tape measure
Pencil
Tape
Cleaning supplies (drop cloth,
vacuum)
Spanner screwdriver #6
For doors more than 2 1/2" thick up to 3 3/4", order the
appropriate hardware bag to receive the correct length of
spindles and mounting screws. Part# 062-510189-XXX;
(XXX = choice of finish).
iFor outdoor installations, order gasket 033-512017-1.
i

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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Notes: D: American Standard Mortise illustrated.
A
C
H
B
N
F
D
S
G
J
J
L
I
E
K
B1
D1
C1
A1
E1
2.2 ASM, ESM, 79M Standard Mode (For Cylindrical, see Appendix B)

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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Notes: D: American Standard Mortise illustrated.
A
C
H
B2
W1
W2
N1
H1
N
F
D
S
G
J
J
L
I
E2
K
B3
D1
C1
A1
E1
2.3 ASM, ESM, 79T Toggle Mode (For Cylindrical, see Appendix B)

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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For Right Hand Lock
Autodeadbolt
Right Hand
Autodeadbolt
Left Hand
ASM Right &
Left Hand
For Left Hand Lock
E2
M2
M2
N1 N1L L
LEVER
2.4 Autodeadbolt; ASM Inside Trim Assembly for 79T (Toggle Mode)
(for 79M standard mode with Autodeadbolt; ASM Office and ASM/ESM Storeroom models, use parts (M) as shown in Appendix
A2)
NOTE: The inside trim assembly (E) for ASM and ADB on 79T models includes the parts (M) as shown below. Position of stopper
M2 is very important
2.5 Cylindrical Unit and Inside Trim Assembly for 79M Standard Mode see Appendix B
2.6 Inside Trim Assembly 79T Toggle Mode Cylindrical

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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3 • Installation of Standard ASM OR ESM Models
3.1 Check the Mortise Handing
Compare the mortise with the diagram below. If the
mortise is the correct handing for the door, continue
with step 3.2.
Refer to Appendix A.1 to change the handing of a
field-reversible mortise.
i
For LH (left hand) and
RHR (right hand reverse)
For RH (right hand) and
LHR (left hand reverse)
ASM
For LH (left hand) and
RHR (right hand reverse)
For RH (right hand) and
LHR (left hand reverse)
ESM
Door Handing (Top View)
Right Hand (RH)
Left Hand (LH)
Right Hand Reverse (RHR)
Left Hand Reverse (LHR)

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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3.2 Install the Strike
1. Align the paper template on the door frame at the desired
handle height ( ), and along the vertical center line of the
mortise (CL), which is also the center line of the door edge,
allowing for any bumpers on the door frame.
Respect applicable building codes regarding handle
height.
Note that the centerline of an ESM mortise does
NOT pass through the screw holes on the strike.
!
2. Mark the locations of the dust box cutout and mounting
screws for the strike.
3. Mortise the door frame to receive the dust box, and drill the
pilot holes for the mounting screws (dimensions and depths
marked on template).
4. Position the strike against the doorframe and align it with the
mounting screw holes. Trace the outline of the strike.
5. Remove material from within the strike outline so that the
strike will be flush with the doorframe.
6. For ASM, install the dust box (optional for wood door frames,
required for metal door frames), and check the strike handing
on the template. Install the strike using the screws provided.
Use wood screws for wood frame and machine screws for
steel frames.
When strike is installed on wood frames under one
inch thick, wood screws supplied are not adequate. use
screws of efficient length to engage the structural stud
behind the frame. Use only the strike and dust box sup-
plied. Use of non-approved parts may void the warranty.
!
(CL)

PK3561_10_09 • 79 SERIES INSTALLATION GUIDE
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If using the installation jig to prepare the door, refer to the
instructions provided with the jig, then proceed with step
6 below.
i
1. Mark the handle ( )
height on the edge of the door,
as determined directly from the
strike.
For ASM, the axis of rotation
of the handle is level with the
bottom lip of the strike.
For ESM, the axis of rotation of
the handle is 1-1/4" above the
bottom lip of the strike.
For cylindrical models, see B2
in Appendix B
2. Align the template along the
vertical center line of the mor-
tise (CL) at the desired handle
height, and tape it to the door.
Mark all holes and cutouts for the mortise in the edge of the
door and remove the template.
3. Locate the two sets of vertical fold lines on the template
allowing you to adjust the positioning of the template depend-
ing on the bevel of the door.
If the door has no bevel, fold the template along the solid lines.
Align the fold with the edge of the door and mark the holes for
the lock. Repeat on the other side of the door.
If the door has a 3º bevel, fold and align the dashed line
marked “H" on the template with the higher-beveled edge
of the door and mark the lock holes on that side of the door.
Repeat on the side with the lower-beveled edge using the
dashed line marked “L". Remove the template.
4. Prepare the cut-outs for the mortise in the edge of the door
using a mortising machine, router and chisel (for dimensions,
refer to template).
Ensure clearance is provided for moving latch parts as indi-
cated on the template.
5. Drill the holes in the sides of the door (for dimensions, refer
to template).
Drill from both sides of the door to prevent unsightly
damage
!
6. For ASM only, check the bevel of the mortise. If adjust-
ment is required, loosen bevel screws (R) and adjust mortise
front plate angle to match the bevel of the door. Re-tighten
screws.
Install the mortise with 2 screws (Q). Use wood screws for
wood doors and machined screws for steel doors.
Install mortise faceplate (P) with the two 8-32 x 1/4" screws
provided.
The ESM faceplate must be installed so you can read the
logo (see arrow in figure above right-side-up for proper
operation.)
!
3.3 Install the Mortise
ESM
Strike
(ESM)
ASM
Strike
11 /4"
Door
(CL)
2
5
4
3
RH/LHR (ASM shown) LH/RHR
Logo
P
Q
R
R