Kaba Mas Gitcon G-152 User manual

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Gitcon Model G-152
Installation Guide
for Swing & Roll-Up Doors
G-152 Parts
1. Lock Body Gasket
2. Lock Body mounting bolts and washers
3. Lock Body with cable
4. Input Unit mounting bolts and washers
5. Input Unit
6. Handle (6a. Roll-Up or 6b. Swing)
7. Handle Mounting Hardware (Not shown in photo)
8. Back Plate (8a. Vertical or 8b. Horizontal)
9. Cable Routing Plate (9a. Vertical or 9b. Horizontal)
10. Test card (not shown).
Document Number 607.106 Rev. B - 4/08
Fig. 1 - Lock Body & Input Unit Parts
Fig. 2 - Vertical and Horizontal Plates Fig. 3 - Roll-Up Handle & Swing Handle
1
2
3
4
5
8a 9a
9b
8b
6a
6b

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Symbol Denitions
WARNINGS - Hazards or unsafe practices which could result in personal injury or product or
property damage.
NOTES - contain important information and useful tips on the operation of your equipment.
Basic Tools and Materials Required
• Fournewhighquality(Energizer®, Duracell®, etc.) AA lithium batteries
• Poprivetgun
• Electrichanddrill
• 8mm(5/16"),10mm(3/8")and16mm(5/8")drillbit
• Appropriatesizeddrillbitfordrillingrivetheadonhandle(ifrivetISNOTstainlesssteel)
• Handheldpowergrinder(ifrivetISstainlesssteel)
• Tape
• Centerpunch
• Adjustableopenendwrenchor10mmand13mm(11mmisalsoneededonroll-updoor
installations)sockets/boxwrenches
• Level
• Hacksaw
• Hammer
• Phillipsscrewdriver
• Tapemeasure/Ruler
• 2mmAllenWrench(inputunitbackcover)
Before Drilling
Before drilling any holes ensure that:
• Youarewearingsuitableeyeprotection.
• Adequateprotectionisttedaroundthesurroundingareatoprotectsuchthingsascables,
water/airpipes,etc.,fromdamage.
Before starting any work, determine the position the G-152 is to be located, bearing in mind
the following points:
• Ensurethereisnoobstructionontheinsideofthedoor.
• Ensurethevehicleisparkedonat,levelgroundwheninstallingthislock.
• Pleaserememberyouareinstallingahighquality,precisionlocktoadoorwhich,evenwhen
new,willhaveafairamountoffreeplayinitsoperation.Thisfreeplaywillonlyincrease
withwearasthevehicleisused;therefore,greatcaremustbetakenduringinstallation.
Input Unit Preparation
RemovethebackoftheInputUnit(4screws)witha2mmAllenWrench.Placefournewhighquality
AA lithium batteries in the battery retainers. Reattach the back plate, ensuring that the wires are
notpinched.Oncethebatteriesareproperlyinstalled,redLEDlightwillash.Connectthecable
tothelockbody.PerformtheOperationalCheck(p.7).Disconnectthecable.
WARNING
!
WARNING
!

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Remove Existing Handle
Note: Useacenterpunchtomarktherivetheadbeforeattemptingtodrilltheheadoff.This
willhelppreventthelikelihoodofthedrillslippinganddamagingthevehicledoor.Ifthe
rivetisstainlesssteel,apowergrindermayberequiredtogrindofftherivethead.
1. Grindordrilljustenoughtoremovetherivetheadandtoavoiddamagingthedoor.Oncethe
headhasbeengroundordrilledoff,knocktheremainsoftherivetoutusinganappropriate
sizedpunch.Removethehandlefromthedoor.(SeeFigure4.)
Note: Roll-updoorswillhavemultiplerivetsthatneedtoberemoved.(SeeFigure5.)
Remove Handle Retainer or Keeper Assembly
1. Drill/grindtheboltsoutofthehandleretainerassembly(forswingdoor)orthehandlekeeper
(forroll-updoor).(SeeFigure6forSwingDoorandFigure7forRoll-UpDoor.)
2. Removetheretainerorkeeperassembly.
Fig. 4 - Swing Door Fig. 5 - Roll-Up Door
Fig. 6 - Swing Door Fig. 7 - Roll-Up Door
Keeper

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Install Handle
Swing Door
1. AttachtheG-152handletothehubwheretheoldhandlewasremoved,usingthepinincludedin
the kit. Insert the pin from the front side of the locking bar.
2. Gainaccesstotherearofthepin.Insertwasherandrivetincludedinthekit.Securetherivetin
positionusingthepoprivetgun.
Note: Ifinstallingonadoorwithdoubleverticallockingbars,installonthelockingbarclosest
to the hinges.
Roll-Up Door
1. Withthedoorclosed,alignthedoorhandleassembly"J"hookwiththecenterpin/plateofthelatch
box.Operatehandle(open/close)toensurecorrectpositionwithinthelatchbox.
2. Ensurethehandleislevel.Usetheatendofthehandle.(Seegure8.)
3. Using the handle assembly mounting bracket as a template, mark (center punch) the location of
the mounting holes.
4. Drillthehandleassemblymountingholesusingan8mm(5/16")drillbit.
5. Insert and seat carriage bolts into supplied handle assembly. Seat carriage bolts by using a hammer
todrivetheboltsintothemountingplate.
6. Mount handle assembly to door and secure from the inside with washer/lock washer/nuts
provided.
Note: Ifnecessary,useahacksawtoremove
excess bolt length and grind any
resulting sharp edges.
Prep Door for Lock Body
1. Using the new handle, close the door(s) fully,
ensuring correct shutting for closed position.
2. Aligntemplaterelativetothelockingpinon
thehandle.(SeeFigure8.)
3. Use tape to secure the template to the door.
4. Place the lock body over the coordinating
location on the template and rotate the handle
to ensure that it clears the lock body. If not, readjust the template.
Note: If the handle becomes locked in position, connect the cable from the input unit to the lock
bodyandperformtheOperationalCheck(p.7)tounlockandliftthehandle.
5. Center punch all four mounting holes and cable routing hole.
6. Removethetemplate.
8. Drillthefouroutsidelockcasemountingholesusinga10mm(3/8")drillbit.
9. Drillthecableroutingholeusinga16mm(5/8")drillbit.
Note: Ensurethatthedrilliskeptstraightwhendrillingtheholes.
Fig. 8 - Align Template to Handle
FlatonHandle
Locking PIN
Electronic
LockOnly
Cable
Routing Hole

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 Deburralldrilledholes.Removealldebrisfromtheworkareaafterdrillingandbeforeproceeding
furtherwithanyinstallation.DONOTusecompressedairtoremovedebris.Flyingobjectscan
cause serious injury.
Prep Door for Input Unit
1. Temporarily attach the cable routing plate to the front of the door for use as a template, using
thelockmountingscrewstoholditinplace.(SeeFigure9.)
2. Center punch four mounting holes for the Input Unit.
3. Measureandmarkanadditional16mm(5/8")holeforcableroutingapproximately32mm
(11/4")fromthetopofthecableroutingplate.(SeeFigure10.)
4. Removethecableroutingplate.
5. Drillthecableroutingholefortheinputunitusinga14mm16mm(5/8")drillbit.
6. Drillthefourmountingholesfortheinputunitusinga10mm(3/8")drillbit.
Install Lock Body & Input Unit
Note: ForRoll-UpDoorapplicationsusingaTodco(orWhitingGeneralPurpose)handle,
use the longer 8mm mounting bolts supplied for the bottom two holes of the lock body
and use the longer 6mm mounting bolts supplied for the bottom two holes of the input
unit.
1. Start to attach the two cable routing plates to the inside of the door using two of the lock body
mounting bolts and two lock washers. Attach through the upper right and lower left corners of
the lock body mounting holes.
2. Ontheoutsideofthedoor,placethelockbodygasketoverthetwoboltstoholditinplace.
3. Whileholdingthelockbody,routethecablethroughthegasketandthecableroutingholefor
the lock body.
Fig. 9 - Use Cable Routing Plate as Template Fig. 10 - Measure & Mark Cable Routing Hole
WARNING
!
1 1/4"

6
4. Secure (hand tighten only) the G-152 lock body
usingthetwobolts.(SeeFigure11.)
Note: Youwillhavetobacktheboltsoutfromthe
inside of the door a small amount in order
to thread them into the lock body.
5. Route the cable through the cable routing hole for
the input unit.
6. Insert two of the input unit mounting bolts and
washers through the back of the door. Use the
upper right and lower left corners of the input unit
mounting holes.
7. Connect the lock body and input unit cable.
8. Placeexcesscablebackintheinputcavityviathe
cable routing hole.
9. Secure (hand tighten only) the input unit using the
twobolts.(SeeFigure13.)
Note: Youwillhavetobacktheboltsoutfromthe
inside of the door a small amount in order
to thread them into the input unit.
10. Tape the cable in place in the routing channel so
that it does not get pinched when the back plate is
attached.
11. Attachthebackplateoverthecableroutingplatewiththefourremainingbolts,ensuringthe
cable does not get pinched. The cable must stay in the channel of the cable routing plate. (See
Figure14.)
12. Securely tighten all bolts.
13. Before closing door, place handle in lock body and perform operational check.
Note: If handle will not go into the lock body, loosen the lock body bolts, reposition lock body
to accept handle and re-tighten bolts.
14. Close the door(s) and place the handle in the lock body.
Installation complete.
Fig. 11 - Secure Lock Body from Back of Door
Fig. 12 - Connect Cable to Input Unit
Fig. 13 - Secure Input Unit from Back of Door Fig. 14 - Attach Back Plate

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Operational Check
PerformtheoperationalcheckpriortoinstallingtheLockassembly.IftheG-152hasbeenpreviously
installed, perform the operational check prior to closing
the door.
Make an operational check of the unit by performing the
followingactions.(SeeFigure15forreference.)
1. Connect the Lock Body and input unit cable.
2. Activatetheinputunitbypressingandreleasingthe
REDswitchbutton.
3. "Open"willappearontheLEDdisplay.
4. Insert (latch) the operating handle locking pin into the
lock body.
5. PressandreleaseREDswitchbutton.
6. Press and release RED button again with "UNLK"
prompt.
7. GREENlightashes.
8. Present Test Card to input unit transponder "RFID"
communication area.
9. Turn dial on lock body to the left to release the handle.
10. Lift operating handle.
Operational check complete.
Battery Maintenance - Temporary Power
Replace Batteries
The four AA batteries located within the Input Unit should be replaced when the “Battery Low Indicator“
illuminates. To replace batteries, complete the following steps:
1. Removetheinputunitfromthedoor(4mountingbolts)anddisconnectcable.
2. Removethebackplateoftheinputunit(4screws)andthefourAAbatteriesinthebatteryretainer.
ReplacethebatterieswithfournewhighqualityAAlithiumbatteries.Oncethebatteriesareproperly
installed,thelowbatteryindicatorlightwillash.
3. Reattach the back plate of the input unit.
4. Reconnect the cable and reinstall input unit.
5. Before closing the door, perform an operational check of the lock with the appropriate opening
procedureasdenedfortheinputunit.
Temporary Power
Anexternal9Vsupplementarypowerconnectorisprovidedtosupplytemporarypowertotheinput
unit. The 9V connector is located at the base of the input unit and is accessible by turning the
knurled knob. It is recommended that you use a new high quality battery.
Fig. 15 - Input Unit Operation
Access to
9 volt connector
Low battery
indicator
Transponder RFID
communication area
IrDA®port;
Communication with
Pocket PC/Smart Phone
LED Lights;
Operational
prompts and
lock status
Switch activates
unit and enters
user cdes
LED displays
seal number
and operational
prompts

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Notice: Informationinthisdocumentissubjecttochangewithoutnotice.KabaMasshallnotbeliablefortechnicaloreditorialerrorsor
omissionscontainedherein;norforincidentalorconsequentialdamagesresultingfromthefurnishing,performanceoruseofthismaterial.
© 2006 Kaba Mas LLC. All rights reserved.
Kaba Mas LLC
749 W. Short Street, Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Technical Support: [phone]
www.kaba-mas.com
Maintenance and Trouble-Shooting
Maintenance
• Inspectthedoorassemblytoassureproperalignmentandoperation.
• InspecttheG-152mounteddoorpanelfordefectsandrepair/replaceasrecommendedbythe
manufacture.
• Verifylockbodyandinputunitmountinghardwareissecure.
• Openandcloselockassemblytoassureallcomponentsareproperlyalignedandingood
operating condition.
• Inspectphysicalconditionofhandle-mounted"WeatherGuard"andreplaceifneeded.
• KeepLockBodylockingjawscleanandremoveanydebris.
• ApplyaDryFilmLubricanttotheLockBodylockingjaws.
• ReplaceInputUnitbatteriesatleastonceayear.Seepage7BatteryMaintenance.
Winter Conditions
• Iflockbecomesfrozen,applyde-icerasrequiredtothe:
•Lock Body locking jaws
•Lock Body operating dial
• InputUnitREDbuttonswitch
• Applya 9-voltbatterytothesupplementarypowerconnector ifcoldweatherconditions
impairtheInputUnit/LockBodyoperation.Seepage7TemporaryPower.
Trouble-shooting
• IftheInputUnit/LockBodyoperationmalfunctions,applya9-voltbatterytothesupplementary
powerconnector.Ifoperationsresume,replacetheInputUnitbatteries.Seepage7"Battery
Maintenance-TemporaryPower".