Kaba Mas Low Profile 52 series User manual

INSTALLATION GUIDE
LOW PROFILE LOCK

TABLE OF CONTENTS
INTRODUCTION ........................................................................ 1
Design Parameters for Locks ......................................................... 1
Prepare for New Installation of the Lock......................................... 1
Basic Tools and Materials Needed ................................................. 2
Table of Recommended Torques for Lock Screws ........................ 2
Template .......................................................................................... 2
Lock Parts for Installation ............................................................... 3
INSTALLATION ......................................................................... 4
Install the Lock ................................................................................ 4
Install Battery Clip & Battery .......................................................... 9
Test the Lock ................................................................................... 9
UNINSTALL THE KEYPAD ASSEMBLY ......................................... 11
WARNING: Kaba Mas locks are well protected from Electrostatic
Discharge (ESD) damage once they are installed, but can be
damaged during the installation process if proper precautions
are not observed. Follow these precautions to avoid ESD
damage when installing the lock:
• Do Not Touch the end of the flex cable.
• Handle the keypad assembly by the outer edge only.
• For the best protection, use an ESD wrist band grounded to
the lock or container during installation. The lock is pro-
tected to greater than 25,000 V ESD when correctly installed.

1
INTRODUCTION
You should read all instructions carefully before you install and use your Low
Profile 52 Series lock. This will help you avoid unnecessary costs and
concerns resulting from improper installation.
These installation instructions apply to all Low Profile 52 Series Models (Self
Powered and Battery).
Design Parameters for Locks
1. Bolt dimensions (nominal): .312 inches X 1.000 inches / 8 X 25,4 mm
2. Bolt movement (nominal) : .465 inches /11,8 mm
3. Maximum load movable by the bolt: 2,5 N
4. Maximum load against bolt when thrown (all directions): 1kN (maximum)
5. The lock can be fitted to safes or vault doors of any material.
Prepare for New Installation of the Lock
1. Use the template to establish the exact locations (relative to the spindle
hole) of the mounting holes for the lock assembly.
2. The lock case mounting screws (1/4-20) require drilled and tapped holes to
3/8” depth if possible (minimum 1/4” depth required).
3. The spindle hole diameter for spindled installation must be a minimum of
3/8” (9.525mm). The maximum spindle hole diameter of 13/32 inch
(10.32mm) is also the recommended diameter.
4. Deburr the spindle hole, ensuring that there are no sharp edges that could
cut the cable.
5. The dial assembly mounting screws (8-32) require drilled and tapped holes
to 3/8” depth if possible (minimum 1/4” depth required).

2
Basic Tools and Materials Needed
• Medium (#2) and Small Phillips head screwdriver (magnetized tip recom-
mended)
• Fine pitch hacksaw (32 teeth/inch)
• Small flat file
• Pliers
• All-purpose scissors
• Tape measure or ruler
Recommended, but not required:
• Torque screwdriver (30 inch-pounds/3.4 newton-meters capacity).
Table 1 - Recommended Torques for Lock Screws
Application Screw Screw Torque Torque
P/N Size in Lbs N-M
Dial assembly mounting 305089 8-32 17 to 20 1.9 to 2.25
screws
Keypad assembly mounting 305110 6-32 snug snug
screws
Lock case mounting screws 105195 1/4-20 25 to 30 2.8 to 3.4
Template
A template is provided as an aid for locating, drilling, and tapping the lock
mounting screw holes relative to the spindle hole. Since the lock is designed
to fit most industry standard container lock mounting screw hole patterns, the
need to use this template should be minimal.

3
Lock Parts for Installation
1. Lock case assembly
2. Keypad assembly
3. Dial assembly (with home position decal attached to back)
4. Lock case mounting screws (4 for Battery, 3 for Non-Battery)
5. Dial assembly mounting screws (2)
6. Keypad assembly mounting screws (2)
7. Spindle with spring and protective tube (Spring not included for Spring
Bolt)
8. Cable shields (2) (not pictured)
9. Insulator tape (not pictured)
Figure 1 - Lock Parts for Installation
1 JJ
JJ
J
7 JJ
JJ
J
4 JJ
JJ
J
3 JJ
JJ
J
2 JJ
JJ
J
6 JJ
JJ
J5 JJ
JJ
J

4
INSTALLATION
Install the Lock
Warning: Do not take the lock case assembly apart. There are no
field servicable parts inside lock case.
Complete the following steps to install
the lock:
1. Insert a cable shield into the spindle
hole from the back side of the
container door. (See Figure 2.)
2. Place the protective tube on the
tube retainer over the spindle hole
on the lock case. Make sure that
the flex cable is positioned on the
outside of the tube (Figure 3).
Caution: Do not touch the silver
leads on the flex cable. This
could cause ESD damage.
3. While holding the lock case
assembly, carefully guide the
end of the flex cable and the
tube through the container so
that they are easily accessible
at the outside of the container
(Figure 4).
4. Hold the lock case assembly
tightly against the inside of the
container and mark the tube flush (to
within 1/16”) with the outside of the
container door for cutting.
5. Guide the end of the cable and the
tube back through the inside of the
container.
6. Remove the tube from the spindle hole
on the lock case and use scissors to
cut the tube just inside your mark.
Keep the cut as straight as possible.
7. Place the tube back onto the tube
retainer on the lock case. Once again
be sure the flex cable is positioned on
the outside of the tube (Figure 3). Figure 4 - Guide flex cable through
container
Figure 3 - Place tube on tube retainer
Figure 2 - Insert Cable Shield

5
8. Tape the flex cable to the outside of the tube with the insulator tape
provided in the installation kit.
9. While holding the lock case assembly, again carefully guide the end of the
flex cable and the tube through the inside of the container so that they are
easily accessible at the outside of the container.
10. Mount the lock case assembly to the inside of the container door in the
proper orientation using the four lock case mounting screws for a Battery
lock or three screws for Non-Battery lock.
Note: It is recommended that you use Loctite®262 (Red) on the lock case
mounting screws.
11. For Spring Bolt Model:
Insert the end of the spindle with the
screw hole into the lock case assem-
bly until the spindle is properly
seated.
For Dead Bolt Model:
Remove the spring from the spindle
and insert the spring end of the
spindle through the spindle hole on
the container and into the spindle hole
on the lock case (Figure 5). Make
sure that you insert the spindle far
enough into the spindle hole so that it
engages with the cam.
12. The grooved side of the spindle
should be oriented so that the
grooves in the spindle align with the
grooves in the drive cam. Turn the
spindle so that the grooves in the
spindle are facing toward the ex-
tended bolt, if they are not already
oriented in that direction.
13. Mark the spindle shaft 3/16” from the
container door for cutting (minus 1/32”
allowed.) (Figure 6)
14. Remove the spindle from the lock
case to prevent damage to the cable
while cutting.
15. Use the hacksaw to cut the spindle
on the mark.
16. Use a small, flat file to deburr the spindle after cutting.
17. If you are installing a Dead Bolt version of the lock, place the spring back
onto the spring end of the spindle.
Figure 6 - Mark spindle for cutting
Figure 5 - Insert spring end of spindle
into spindle hole

6
Figure 8 - Correct position
Figure 9 - Incorrect position
Red portion is showing
18. For Dead Bolt:
Insert the spring end of the spindle into the container with the grooved side
facing towards the extended bolt. (Figure 5)
For Spring Bolt:
Insert the end of the spindle with the screw hole into the lock case
assembly until the spindle is properly seated. Ensure that the grooved
side of the spindle is facing towards the extended bolt.
19. Insert the second cable shield into
the spindle hole from the front of the
container with the cable feeding
through the center of it. (See Figure
7.)
20. While holding the dial assembly,
make sure that the red mark on the
home position decal is positioned at
the top of the dial (i.e., the lip of the
dial should cover the red area on the
decal) (Figures 8 and 9).
21. There are two available cable receiving holes coming off of the back of the
dial assembly. Guide the flex cable through the appropriate cable receiving
hole based on the orientation in which you are mounting the lock (Figure
10). The cable must be fed through the cable hole toward the outside of
the gear shield (Figure 11). This may cause the gear shield tab to come
out so that it must be reinserted.
Figure 7 - Insert cable shield into
spindle hole
Cable
Shield
Spindle
Flex Cable

7
22. Align the dial assembly with the
spindle and hold the dial assembly
against the container door. Attach the
dial assembly to the container door
using the two dial assembly mounting
screws and the Phillips screwdriver.
Use either the two horizontal mounting
holes or the two vertical holes,
depending on the hole pattern in the
safe. Tighten the screws. (Figure 12)
Caution: Do not touch the silver leads on
the end of the flex cable. This could
cause ESD damage.
23. On the keypad assembly, there are two available ZIF connectors. Depend-
ing on which cable receiving hole the flex cable extends from, you will plug
the flex cable into the appropriate ZIF connector. For example, if the flex
cable comes out of the bottom cable receiving hole, the cable must be
plugged into the top ZIF connector. Pull the release on the appropriate ZIF
connector outward to its open position. Plug the flex cable into the ZIF
connector with the blue leads facing upwards (Figure 13). Close the ZIF
connector to lock the flex cable in place (Figure 14).
Figure 12 - Attach dial assembly
to container
Figure 11 - Cable must be outside of
gear shield
Gear Shield
Flex Cable
Figure 10 - Guide flex cable
through cable receiving hole

8
24. Carefully fold the excess flex cable and
position it in the center area of the lock
case so that the cable will not be
pinched by the gears (Figure 15).
25. Make sure that the flex cable will not be
pinched when the keypad assembly is
in place. Also verify that the dial moves
freely when the keypad assembly is in
place. Once you have verified this,
gently lift the left side of the keypad
decal and screw the keypad assembly
into place using one of the 2-56 flat
head keypad assembly mounting
screws.
26. Gently lift the right side of
the keypad decal and use the
other keypad assembly mount-
ing screw to screw the keypad
assembly into place (Figure 16).
Fig. 16 - Screw keypad assembly into
place
Figure 15 - Fold and position
excess flex cable
Figure 14 - Close ZIF connector
Figure 13 - Open ZIF connector
and insert flex cable

9
INSTALL BATTERY CLIP & BATTERY (Battery or Battery Assist Locks
Only)
1. Remove tape backing from the tape on the battery clip.
2. Mount the battery clip.
3. Connect a fresh 9 Volt Alkaline battery to the battery connector.
4. Insert the battery into the battery clip.
TEST LOCK
Test the operation of the lock before completing the installation of the keypad
assembly decal and prior to closing the container by verifying the following:
• Ensure that all screws on the back of the lock case assembly have
been securely tightened.
• Ensure that the flex cable is not being pinched by the keypad.
• Ensure that the dial turns freely without scraping.
Caution: Scraping may be caused by the gears rubbing on
the flex cable which could result in a lock failure.
• If you are operating a self-powered lock, power the lock by turning the
dial back and forth in both directions until simultaneous green and red
flashes display with a beep.
• Position the lock dial to the HOME position (i.e., the lip of the dial will
cover the red “open lock” indicator) and key in the factory combination
(“50 25 50”). If the combination is entered successfully, one green
flash displays with a beep to indicate that the lock is ready to open.
• To open the lock, turn the dial right (clockwise) until the lock bolt is
retracted.
Note: After correctly entering a valid combination, you must turn the lock
dial to the right within ten seconds. Once you have turned the lock
dial, you must retract the bolt within four seconds (by continuing to
turn the dial to the right). If you do not turn the lock dial to the right
or retract the bolt within the allotted time periods, you will need to
rekey the factory combination to open the lock. You might also need
to power the lock again.
• If the lock opens successfully, you can close a Dead Bolt lock by
dialing left (counter-clockwise) until the lock bolt closes. For a Spring
Bolt, the bolt will “spring” back into the extended position as soon as
you release the dial.

10
Figure 17 - Peel backing from keypad
decal
25. If the lock does not operate successfully, carefully unscrew the keypad
assembly and check the flex cable connection. Also ensure that the flex
cable is not getting pinched.
26. After you have successfully tested the lock operation, ensure that the
keypad mounting screws have been tightened.
27. Peel the adhesive backing from
the left and right sides of the
keypad decal and apply the
decal to the keypad assembly
(Figure 17).
Note: The lock will not open if
excessive force is applied to
the end or side of the bolt.
The installer should check for
these conditions after instal-
lation.

11
UNINSTALL THE KEYPAD ASSEMBLY
If the lock is not operating properly, it may be necessary to uninstall the lock
keypad assembly by completing the following steps:
1. Peel the keypad decal from the
keypad assembly (Figure 18).
(You will need to contact Kaba
Mas to order a new keypad
decal.)
2. Remove the two keypad assem-
bly screws and then gently pull
back the keypad assembly from
the dial assembly.
3. Perform the checks listed in Step
24 on the previous pages to
ensure that the lock has been
installed correctly and test the
operation of the lock again.
4. If the lock still does not operate
successfully, contact Kaba Mas Technical Support at 1 [phone].
Figure 18 - Remove keypad decal

12

NOTES

Document Number 3016.062
Rev. C - 01/03
Notice: The information in this manual is subject to change without notice and does not represent
a commitment on the part of Kaba Mas. 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.
© 2002-2003 Kaba®Mas
All rights reserved
Kaba®Mas Corporation
749 W. Short Street, Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Technical Support: [phone]
www.kaba-mas.com