Kaba 5 00 Series User manual

E-PLEX®
5x00 CylindriCal
installation instruCtions

2
TABLE OF CONTENTS
Assembly Drawing (Model E5031)..........................................................3
Tools Required ........................................................................................3
A. Door Preparation................................................................................4
B. Lock Handing ....................................................................................5
C. Door Thickness ..................................................................................5
D. Installing Outside Unit Assembly .......................................................6
E. Installing Inside Unit Assembly ..........................................................6
F. Installing Inside Lever/Knob...............................................................7
G. Changing Key-In-Lever/Knob (KIL/KIK) Cylinder ..............................8
H. Installing / Removing Outside Lever/Knob.......................................10
(Key-In-Lever/Knob Models)
I. Installing / Removing Outside Lever/Knob.......................................11
(Interchangeable / Removable Core Models)
J. Installing The Battery Pack and Cover/ ...........................................13
Changing Batteries
K. Testing Lock Operation....................................................................14
L. Programming and Software Settings ...............................................15
M. Installing Strike.................................................................................15
N. Installing Rubber Bumpers...............................................................16
Warning
The Master Code of this lock has been factory preset: 1,2,3,4,5,6,7,8.To
activate lock functions, the master combination must be changed at time
of installation.
Warnings and Cautions
Important: Carefully inspect windows, doorframe, door, lights, etc. to
ensure that the recommended procedures will not cause damage. Kaba
Access Control’s warranty does not cover damages caused by installa-
tion.
Caution: Wear safety glasses when preparing door.

3
Model E5031
The E-Plex 5031 is a non-handed lock that is preassembled for
left-hand installations. It is field reversible.
TOOLS REQUIRED
• Safety glasses
• Electric drill (variable speed)
• Awl or center punch
• 2
1⁄8” (54 mm) hole saw pilot drill
• 1” (25 mm) hole saw pilot drill
•1⁄4” (7 mm) drill bit
• 1” (25 mm) wood chisel
• Hammer
• Phillips head screwdriver
• Small flat blade screwdriver
For technical assistance please call
1-800-849-TECH (8324) or 336-725-1331

4
A. DOOR PREPARATION
A-1 Place paper template (supplied) onto door and
mark for holes. Drill the four 1 ⁄4” (7 mm) holes first.
Next drill the 21 ⁄8” (54 mm) cross bore hole. Drill
the 1” (25 mm) hole last.
A-2 Mortise door edge for latch unit faceplate (c)
1 ⁄8” (3 mm) deep to dimensions shown. Insert
latch unit (a) into the 1” (25 mm) hole, making
certain that the latch bolt bevel faces direction
of closing door.
A-3 Secure the latch to the door using two 3⁄4”
(19 mm) combination screws (b) supplied.
Latch unit faceplate must be flush with
door (c).
1”
21⁄8”
11⁄8”
21⁄4”
a
c
b
4x1⁄4”

5
B. LOCK HANDING
The E-Plex 5000 is a non-handed lock that is preassembled for left-hand
door installations.
B-1 Determine the hand of your door. For left hand doors, proceed to Section C.
For right hand doors, follow steps in B-2.
B-2 Remove the two connecting screws (a) from the
cylindrical drive unit (b). Rotate cylindrical drive
unit 180 degrees. Reposition spacer (c) as found
before disassembly. Remount drive unit with the
two connecting screws.
C. DOOR THICKNESS
The E-Plex 5000 lock is preassembled to accommodate standard door
thickness 15⁄8”(41 mm) to 2”(51 mm).
C-1 (Reference Figure A) For thinner door
applications of 13⁄8”(35 mm) to 11⁄2”(38 mm)
remove and discard the two connecting screws (a)
from the cylindrical drive unit (b). Remove and discard
the spacer (c). Remount the cylindrical drive unit using
the two shorter 13⁄8” (35 mm) connecting screws also
supplied.
C-2 (Reference Figure B) For thicker door
applications of 21⁄8”(54 mm) to 21⁄2”(57 mm)
remove the two connecting screws (a) from the
cylinder drive unit (b). Add the extra spacer (c)
supplied. Remount the cylindrical drive unit using
the same two connecting screws (a) just removed.
c
b
a
c
b
a
b
c
a
Figure B
Figure A

6
Note: Installing levers to the unit assemblies before mounting
the unit assemblies may ease initial installation.
D. INSTALLING OUTSIDE UNIT ASSEMBLY
D-1 Slide the drive unit (a) into 21⁄8”(54 mm) cross bore hole
by depressing latch bolt (b) in slightly until the outside
unit assembly (c) rests flush against the door. Ensure
the red collar is seated in the top left mounting hole.
Note: If the red collar appears to be too snug in the
1/4 inch hole, you can enlarge the hole in the door
to 5/16”.
D-2 The drive unit (f) must engage the latch unit
prongs (g) and the shoe retractor (h) must engage
the latch unit tailpiece (i) as shown.
E. INSTALLING INSIDE UNIT ASSEMBLY
Note: Installing levers to the unit assemblies before mounting
the unit assemblies may ease initial installation.
E-1 Slide the drive hub (a) into the drive sleeve (b) and
then guide the red collar on the inside unit (c)
through its respective mounting hole on the door
and carefully push the inside unit flush against
the door.
E-2 Select the LectroBolt (screw with red sleeve)
length that corresponds to the correct door
thickness as noted in this chart:
Door Thickness LectroBolt Size Mounting Screws Size
13⁄8” to 11⁄2”
(35 mm to 38 mm)
23⁄8”
(60 mm)
21⁄2”
(64 mm)
15⁄8” to 2”
(41 mm to 51 mm)
23⁄4”
(70 mm)
27⁄8”
(73 mm)
21⁄8” to 21⁄4”
(54 mm to 57 mm)
3”
(76 mm)
31⁄4”
(83 mm)
c
a
h
i
g
f
c
a
b
b

7
E-3 Insert LectroBolt through the red inside
housing hole marked with the lightening
bolt symbol.
For now, only partially tighten the Lectro
Bolt to keep the red collars in position.
Then, insert and tighten the other three
mounting bolts.
Finish tightening the LectroBolt to secure
the lock on the door.
Warning: If using a power drill, please be careful not to over-tighten as
this could cause damage to the mounting screws and threads.
F. INSTALLING THE INSIDE LEVER/KNOB
Note: Installing levers/knob to the unit assemblies
before mounting the unit assemblies may ease
initial installation.
F-1 Insert the inside lever/knob (a) onto the inside unit
assembly (d). Secure the inside lever/knob with the
3⁄16”(5 mm) set screw (b) (supplied) using the Allen
wrench (c) (supplied).
d
d
b
a
a
LectroBolt
here
LectroBolt
screw
Mounting
screw
c
b
c

8
b
b
a
d
f
c
e
G. CHANGING KEY-IN-LEVER/KNOB CYLINDER
On key-in-lever/knob models of the E-Plex 5000, the outside lever/knob
comes preassembled with Kaba’s key-in-lever/knob cylinder (Kaba 1599).
To use a different key-in-lever/knob cylinder, follow remaining steps in this
section.
G-1 Remove KIL/KIK (key-in-lever/knob) cylinder (a)
from the outside lever/knob (b) by removing the
outside lever/knob sleeve (f). Remove the
cylinder insert (e) (no insert on knobs) and the
cylinder retainer (c) using a small flat blade
screw driver or small needle nose pliers.
TAILPIECE KIL/KIK CYLINDER
K1
Abloy 5277, Abloy 5477, Assa 65691,
Kaba 1539, Kaba Gemini 4730
K2
Assa 65611, Australian: Kaba experT 107K5 &
Boyd KC286, Corbin-Russwin 2000-03, Kaba
1599, Schlage 23-001, Schlage Primus 20-760,
Kaba Peaks 1099
K3 Medeco 20W200H1
K4 Arrow C100, Sargent 10 LINE
K5 Marks
G-2 Determine the proper tailpiece from the chart above for your KIL/KIK
cylinder.
You must use a Kaba tailpiece. The K 2 tailpiece is preassembled with
the Kaba 1599.
a
d
f
c

Kaba Access Control warrants this product to be free from defects in material
and workmanship under normal use and service for a period of three (3) years.
Kaba Access Control will repair or replace, at our discretion, 5000 Series Locks
found by Kaba Access Control analysis to be defective during this period. Our
only liability, whether in tort or in contract, under this warranty is to repair or
replace products that are returned to Kaba Access Control within the three (3)
year warranty period.
This warranty is in lieu of and not in addition to any other warranty or condition,
express or implied, including without limitation merchantability, fitness for pur-
pose or absence of latent defects.
ATTENTION: This warranty does not cover problems arising out of improper
installation, neglect or misuse. All warranties implied or written will be null and
void if the lock is not installed properly and/or if any supplied component part is
substituted with a foreign part. If the lock is used with a wall bumper, the war-
ranty is null and void. If a doorstop is required, we recommend the use of a
floor secured stop.
The environment and conditions of use determine the life of finishes
on Kaba Access Control products. Finishes on Kaba Access Control products
are subject to change due to wear and environmental
corrosion. Kaba Access Control cannot be held responsible for the
deterioration of finishes.
Authorization to Return Goods
Returned merchandise will not be accepted without prior approval. Approvals
and Returned Goods Authorization Numbers (RGA Numbers) for the 5000
Series are available through our Customer Service department in Winston-
Salem, NC [phone]. The serial number of a lock is required to obtain
this RGA Number. The issuance of an RGA does not imply that a credit or
replacement will be issued.
The RGA number must be included on the address label when material
is returned to the factory. All component parts including latches and strikes (even
if not inoperative) must be included in the package with return. All merchandise
must be returned prepaid and properly packaged
to the address indicated.
* Simplex 5000 locks are warranted three (3) years from date of purchase.
E-Plex 5x00 locks are warranted three (3) years from date of activation.
KABA SIMPLEX®/E-PLEX®5x00 SERIES
LIMITED WARRANTY

KABA ACCESS & DATA SYSTEMS AMERICAS 2941 INDIANA AVE WINSTON-SALEM, NC 27199-3770
PLACE
STAMP
HERE

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What was your reason for buying this lock? Who installed your lock?
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Register your Kaba lock online at www.kaba-adsamericas.com/register or fill in this product registration card and return to Kaba Access & Data Systems Americas (postage required to mail). Name Title Company Address City State Zip Country Phone Email Name of Dealer Purchased From Date of Purchase Lock Model Number Serial Number
This lock will be used in what type of facility?
❏Airport
❏Commercial Building
❏Daycare/Childcare
❏Education — ❏ K-12 Facility, ❏ College/University
❏Financial/Bank
❏Government
❏Hospital/Healthcare
❏Industrial/Manufacturing
❏Military/DOD Operations
❏Public Safety
❏Residential
❏Retail
❏Telecommunications/Utilities
❏Other
This Kaba Lock is:
❏A new installation
❏Replacing a conventional keyed lock
❏Replacing an electronic lock (specify brand)
❏Replacing a mechanical lock (specify brand)
What area is being secured with this lock? (e.g., front/back door, cabinet, common door, office)
❏Check here to be advised of important product
and software updates
IMAN

10
b
a
e
c
db
a
d
c
d
G-3 Assemble the required tailpiece (d) (supplied) with
your KIL/KIK cylinder. All tailpieces must be
installed vertically (with key removed from
cylinder) for proper installation.
G-4 Insert the KIL/KIK cylinder (a) into the outside
lever/knob (b) and secure it with the cylinder
retainer (c) and lever insert (e) (no insert on
knobs). The KIL/KIK cylinder should be snug
and unable to move freely.
H. INSTALLING / REMOVING OUTSIDE LEVER/KNOB
(Key-In-Lever/Knob models only)
Note: Installing lever/knob to the unit assemblies
before mounting the unit assemblies may ease initial
installation.
H-1 Make certain the lever catch is up as shown (c).
The lever catch should be flush around the outer
diameter of the outside driver. Make certain the
lever sleeve (f) is rotated to properly mate with the
outside lever/knob.
H-2 Insert one of the supplied keys (a) into the
outside lever/knob cylinder (b) and rotate key
counterclockwise 45 degrees.
H-3 Insert the outside lever/knob (b) until it is flush to
the outside unit assembly (levers fit closer than
knobs). Secure the outside lever/knob by rotating
the key clockwise 45 degrees to the horizontal position.
Remove key.
LH
KIL Lever Sleeve
RH
f
b
b
a
a
45º
c
Correct
Position
Incorrect
Position

11
Note: To remove the outside lever/knob from
the outside unit assembly, follow step below.
H-4 Insert one of the (supplied) keys (a) into
the outside lever/knob (b) and rotate it
counterclockwise 45 degrees. Insert
release tool (d) into the small hole (e)
under lever/knob as shown. Gently
push lever catch up until it clicks.
Remove tool (d), then remove outside
lever/knob (b).
I. INSTALLING / REMOVING OUTSIDE
LEVER/KNOB
(Interchangeable / Removable Core Models)
Note: Installing lever/knob to the unit assemblies
before mounting the unit assemblies may ease
initial installation.
I-1 Make certain the lever catch is up as shown in the
image (c). The lever catch should be flush around
the entire diameter of the outside driver. Make certain
the lever sleeve (f) is rotated to properly mate with
the outside lever.
I-2 Insert the outside lever/knob (a) unit it is flush
to the outside unit assembly (b) (levers fit closer
than knobs). To secure the outside lever/knob,
insert the release tool (d) (or screwdriver) into
the outside lever/knob as shown, and slide the
lever catch down until it clicks. Make certain
lever/knob is locked on.
b
b
a
a
d
d
a
e
e
b
b
45º
d
d
IC Lever Sleeve
RH
LH
f
c
Correct
Position
Incorrect
Position

12
b
e
I-3 Insert the supplied tailpiece (e) vertically into the
outside lever/knob (b) as shown. Make certain that
you rotate the tailpiece so it will align with the inter-
changeable core. For screw cap type cylinders
(Schlage) (g), the tailpiece must be assembled
to the cylinder first with the tailpiece vertically as
shown. Insert the core into the outside lever/knob.
Note: To remove the outside lever/knob from
the outside unit assembly, follow steps below.
I-4 Remove the interchangeable core (g).
Then remove the tailpiece (e).
Note: You may want to use needle nose
pliers for some tailpieces.
I-5 Insert the release tool (d) into the
small hole (f) under lever/knob as
shown. Gently push lever catch up
until it clicks. Remove tool (d), then
remove outside lever/knob (a).
I-6 For ASSA/Medeco/Yale
interchangeable/removable cylinders, the
tailpiece must be prepped for the desired length
before installation.
When using a Yale cylinder on a
cylindrical latch application, measure the
door thickness of the intended application.
I-7 Notice the score marks on the flat portion
of the ASSA/Medeco/Yale tailpiece. Using
the diagram below, locate the score mark
on your tailpiece that matches your
cylinder prep for the intended application,
and break the tailpiece off accordingly.
vertical
g
b
e
a
f
daf
d
eg

13
I-8 Using two pairs of pliers, break the tailpiece to the desired length of the
intended application by holding one pair of pliers on the good side of the
score mark and a second pair on the other side of the score mark. Slowly
move the 2nd pair of pliers up and down until the unneeded portion of the
tailpiece breaks free.
I-9 Insert the Medeco tailpiece (e) vertically
into the outside lever as shown. Make certain that you rotate the tailpiece
slightly so that it will align with the interchangeable/removable cylinder.
Insert the interchangeable/removable cylinder into the outside lever.
J. INSTALLING THE BATTERY PACK AND COVER /
CHANGING BATTERIES
J-1 To install the battery pack (f) and cover
(g), snap the cable connector (c) onto
the top of the battery pack. Then place
the battery pack into the cover, terminals
at the top. Put the two security screws
(h) into the cover and fasten the cover
to the inside housing with the security
screw tool (i).
Caution: Over-tightening these screws could strip the threads in the housing or
crack the cover.
Warning: If the lock goes without power for more than 2 minutes, you will lose
the lock’s current date and time only. If this happens, program the lock with
current date and time. Refer to Operations Manual.
J-2 To change batteries remove the two screws (h) from the battery cover (g)
fastened to the top of the inside housing using the security
screw tool (i) provided with your lock.
J-3 Remove the four depleted batteries and install four new
Alkaline (only) AA batteries. Ensure that each battery
is installed in the proper direction as shown at each
battery location in the battery holder (f).
Warning: Do not install a 9V battery. This E-PLEX lock operates on
4 alkaline only AA batteries (6V). A 9V will ruin the electronics in the
lock and void the warranty.
f
g
h
i
c
f

14
J-4 Reconnect the battery cable. Place the battery holder into the cover.
Screw the back cover onto the inside housing, and ensure that the cable is
not trapped under the edge of the cover.
Caution: Over-tightening these screws could strip the threads in the housing or
crack the cover.
K. TESTING THE OPERATION OF THE LOCK
K-1 Rotate inside lever/knob and hold. Ensure that the latch is fully retracted
and flush with the latch faceplate. Release the inside lever/knob; the latch
should be fully extended.
K-2 Enter the factory-set combination: 1,2,3,4,5,6,7,8. You should see a
green light and hear a high pitched tone as you push each button. When
the lock opens, you will briefly hear the sound of an electronic motor. If
1-2-3-4-5-6-7-8 does not seem to work, please follow the steps to perform
a hard reset by following the procedure in section L.
K-3 Rotate outside lever/knob and hold. Ensure that the latch is fully retracted
and flush with the latch faceplate. Release the outside lever/knob; the
latch should be fully extended. When the lock re-locks, you will again hear
the motor.
K-4 Insert key into the outside lever/knob. Rotate key counterclockwise to stop
position and hold. Ensure that the latch is fully retracted and flush with
the latch faceplate. Rotate key clockwise to horizontal position and
remove key. The latch should be fully extended.
Note: Refer to the Operating Manual to set up lock operation.

15
L. PROGRAMMING AND SOFTWARE SETTINGS:
L-1 You must change the master Code from the factory default to another code
to program the lock. For further information on how to manually program
the E-Plex 3x00/5x00 Series Models, refer to the companion “E-Plex
3x00/5x00 Operation Manual.” Software is required to program the
E3200/E5200 Series Locks.
L-2 When configuring the E3000/E5000 Series Locks using the optional
Standard Software, choose the box that contains “Entry Lock with
Passage (Cylindrical or Mortise without Deadbolt)” during lock setup.
L-3 When configuring the E3200/3700 and E5200/E5700 Series Locks
using the Enerprise Software, select the appropriate lock type during
lock setup.
M. INSTALLING THE STRIKE
Note: The latch and strike provided must be used.
M-1 Mark location of strike on the door frame,
making certain that the strike opening is
aligned (a) with latch bolt.
M-2 Mortise doorframe for strike 3⁄32”(3 mm) deep
minimum to dimensions shown. Secure strike
(b) to the door frame using two 1”(25 mm)
combination screws (c) (supplied).
a

16
a
b
Correct
Incorrect a
b
Caution: Check the operation of the latch by
making sure that the deadlatch (a) stops
against the strike (b) as shown and does not
slide into the strike opening when the door
is closed. If that situation occurs, then a
total lockout may occur. This will void our
warranty of the complete lock mechanism.
If necessary, correct the door over-travel by
using the rubber bumpers as described in
Section N (Installing Rubber Bumpers).
N. INSTALLING RUBBER BUMPERS
N-1 Close the door and apply pressure making sure
the deadlatch (a) rests on the strike plate (b) as
shown. Standing on the frame (door stop) side
of the door, check for gaps between the door
and the frame on the three sides of the frame
(left, right, and top).
N-2 Mark locations where the gaps are
approximately
3⁄16”(5 mm). Make sure these
locations are free from grease and dust.
Peel the bumpers (c) (supplied) from their
protective backing without touching the
adhesive surface and stick them on the
marked locations.
Note: Allow 24 hours for adhesive to set before testing. The door may be
operated normally during this time.
c

Kaba Access & Data Systems Americas
2941 Indiana Avenue
Winston-Salem, NC 27105 USA
Tel: [phone] [phone]
Fax: [phone] [phone]
www.kaba-adsamericas.com PKG2992 08-22