Kaba E-PLEX 2000 User manual

E-PLEX®2000 and 2400 Series
E-PLEX®PowerStar 2000 and 2400 Series
INSTALLATION INSTRUCTIONS

TABLE OF CONTENTS
A. Cylindrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
B. Mortise Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
C. Exit Trim Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
D. Installing Outside Lever on Non-Mechanical Override . . . . . . . . . . . . . . . . .36
E. Reversing the Outside Lever for Series Without Mechanical Override . . .36
F. Installing Optional K-I-L Key or Best Removable Core . . . . . . . . . . . . . . . . .37
Override and Outside Lever
G. Testing the Operations of the Outside Lever . . . . . . . . . . . . . . . . . . . . . . . . .39
H. Testing the Mechanical Key Override with Change Key . . . . . . . . . . . . . . . .40
I. Changing Lock Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
J. Changing Best-Type Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
K. Removing and Reassembling the Outside Lever . . . . . . . . . . . . . . . . . . . . . .42
L. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
M. Installing Battery Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
N. Testing the Operation of the Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Warranty card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .center of book
For technical assistance, call 1-800-849-TECH (8324) or 336-725-1331
Please read and follow all directions carefully.
These instructions are designed for use by maintenance professionals or lock
installers who are familiar with common safety practices and competent to per-
form the steps described. Kaba Access Control is not responsible for damage
or malfunction due to incorrect installation.
Important: Carefully inspect windows, doorframe, door, etc. to ensure that the
recommended procedures will not cause damage. Kaba Access Control stan-
dard warranty does not cover damages caused by installation.
2

A. CYLINDRICAL
CHECKLIST
Parts and Tools List
Each E-Plex 2xxx lockset includes:
• Outside lock housing
• Inside lock assembly
• Outside lever
• Gasket for outside lock housing (not for PowerStar versions)
• Cylindrical latch
• Cylinder drive unit
• Battery holder with 3 AA batteries (not included in PowerStar versions)
• Drilling templates
• Hardware bag, includes:
- Square spindle
- Phillips screw (6-32 x 5⁄16") (not for PowerStar versions)
- Strike kit
- (3) mounting screws (12-24, 1⁄8" hex head)
- Allen Key 1⁄8" — Allen Key 5⁄64"
- (2) 1" (25 mm) Phillips mounting screws
- (1) extension spring
- (4) pairs of Flat Head screws 10-24
- (3) spacers
• Key Override (Optional)
- (1) cylinder with 2 keys for override (if equipped)
- (1) cylinder plug (if equipped)
- (1) cylinder cap (if equipped)
- (2) adaptors for best-type cylinders (if equipped)
- (1) override shaft tool (if equipped)
Warning: For E-Plex 20xx locks, 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 the time of installation.
For E-Plex 24xx locks, you will have to generate an access code using the web
application to test the lock operation.
3

4
DIAGRAM OF LOCK:
BackFront
(A)
(D)
(B)
(E)
(F)
(G)
(H)
(I)
(J)
(C)
TOOLS REQUIRED:
TOOLS REQUIRED:
• Safety glasses
• 1⁄2" (13 mm) chisel
• 1⁄8" (3 mm) drill bit
• 1⁄2" (13 mm) drill bit
• 7⁄8" (22 mm) drill bit or hole saw
• 1" (25 mm) drill bit or hole saw
• 21⁄8" (54 mm) hole saw
• Drill
• Awl or center punch
• Rubber mallet
• Small flat screwdriver (less than 1⁄8")
• Phillips screwdriver (#2)
• Fine steel file
• Router
• Adjustable square
• Tape measure
• Pencil
• Tape
• Cleaning supplies (drop cloth,
vacuum)
• Spanner screwdriver #6
(A) Lock housing
(B) Inside drive hub
(C) Nylon washer
(D) Drive tube
(E) Lever catch
(F) Countersink
(G) Outside Lever
(H) Cap (if equipped)
(I) Cylinder (if equipped)
(J) Cylinder plug (if equipped)

5
A-1. Door Preparation
Note: Drill from both sides of the door to prevent unsightly damage.
1. Determine which template fits your E-Plex 2xxx installation (either the
23⁄8" [60 mm] Backset or the 2 3⁄4" [70 mm] Backset).
2. Place appropriate paper template (supplied) onto door and mark for
holes. Drill the three 1⁄2" (13 mm) holes first. Next drill the 2 1⁄8" (54 mm)
cross bore hole. Drill the 1" (25 mm) hole last.
3. Mortise door edge for latch unit faceplate 3⁄16" (5 mm)
deep to dimensions shown. Insert latch unit into the
1" (25 mm) hole, making certain that the latch bolt
bevel faces direction of closing door.
4. Secure the latch to the door using two 1" (25 mm)
Phillips Mounting screws supplied. Latch unit
faceplate must be flush with door (for doors with
1" diameter hole, use sleeve on latch).
A-2. LOCK HANDING
The E-Plex 2xxx is a non-handed lock
that is preassembled for left-hand
door installations.
1. Determine the hand of your door. For Left Hand doors, proceed to section C.
For Right Hand doors, follow steps below.
2. Remove the two connecting screws from the
cylindrical drive unit. Rotate cylindrical drive
unit 180º. Reposition spacer(s) as found
before disassembly. Remount drive unit with
the two connecting screws.
D
Closing Direction
Left Hand Left Hand Reverse Bevel
LEFT HAND DOOR
Right Hand Right Hand Reverse Bevel
RIGHT HAND DOOR
LH Assembly RH Assembly
Cylindrical Drive Unit Position

A-3. DOOR THICKNESS
Depending on the kind of spacers shipped with the lock, choose Table 1 or
Table 2 to prepare the attachment plate and cylindrical drive unit for door
thickness different than 1 3⁄4" assembled in the factory.
Note: It is very important to assemble the spacers in the position shown.
1. LOCK WITH 3 DIFFERENT SPACERS
The cylindrical unit and plate assembly is
shipped assembled in factory for 1 3⁄4"
(44 mm) door thickness (1 11⁄16" [43 mm]
to less than 1 7⁄8" [48 mm]) with 2 spac-
ers "04"; 1 spacer "02" and 2 flat head
screws 5⁄8" (16 mm) LG. For other door
thicknesses, use Door Thickness Table 1
for appropriate spacers and screws
included in the hardware bag.
Prepare attachment plate and
cylindrical drive unit for door
thicknesses less than 1 11⁄16"
(43 mm) or 1 7⁄8" (48 mm) and
above according to the
Door Thickness Table 1.
Door Thickness Table 1
Door Spacer Spacer Spacer Screw
Thickness 02 04 05 length
13⁄8" (35 mm) to - 1 - 3⁄8"
19⁄16" (40 mm) (10 mm)
Over 1 9⁄16" (40 mm) to - 2 - 1⁄2"
less than 1 11⁄16" (43 mm) (13 mm)
13⁄4" (44 mm) DOOR 1 2 - 5⁄8"
111⁄16 (43 mm) to less than 1 7⁄8" (16 mm)
17⁄8" (48 mm) to 1 - 1 5⁄8"
115⁄16" (49 mm) (16 mm)
Over 1 15⁄16" (49 mm) to 2 - 1 3⁄4"
less than 2 1⁄8" (54 mm) (19 mm)
21⁄8" (54 mm) to - 1 1 3⁄4"
23⁄16" (56 mm) (19 mm)
Over 2 3⁄16" (56 mm) to 2 1 1 7⁄8"
23⁄8" (60 mm) (22 mm)
Over 2 3⁄8" (60 mm) to - - 2 7⁄8"
21⁄2" (64 mm) (22 mm)
6
Screws
Cylindrical
Unit
Assembly
05
04
02
Spacers
Attachment
Plate
Correct Position of Spacers
See Table 1

2. LOCK WITH 2 DIFFERENT SPACERS
The cylindrical unit and plate assembly is
shipped assembled in factory for 1 3⁄4"
(44 mm) door thickness up to 1 13⁄16" [46
mm] with 2 spacers "07"; 1 spacer "08"
and 2 flat head screws 5⁄8" (16 mm) long.
For other door thicknesses, use Door
Thickness Table 2 for appropriate spacers
and screws included in the hardware bag.
Door Thickness Table 2
Door Spacer Spacer Screw
Thickness 07 08 length
13⁄8" (35 mm) to 1 9⁄16" (40 mm) 2 - 3⁄8" (10 mm)
15⁄8" (41 mm) to 1 11⁄16" (43 mm) 1 1 1⁄2" (13 mm)
13⁄4" (44 mm) to 1 13⁄16" (46 mm) 2 1
5⁄8" (16 mm)
17⁄8" (48 mm) to 1 15⁄16" (49 mm) - 2 5⁄8" (16 mm)
2" (51 mm) to 2 1⁄16" (52.5 mm) 1 2 3⁄4" (19 mm)
21⁄8" (54 mm) to 2 3⁄16" (56 mm) 2 2 3⁄4" (19 mm)
21⁄4" (57 mm) to 2 5⁄16" (59 mm) - 3 7⁄8" (22 mm)
23⁄8" (60 mm) to 2 1⁄2" (64 mm) 1 3 7⁄8" (22 mm)
7
Screw Length Full Scale
Length 3⁄8"(10 mm)
Length 1⁄2"(13 mm)
Length 5⁄8"(16 mm)
Length 3⁄4"(19 mm)
Length 7⁄8"(22 mm)
Correct Position of Spacers
See Table 2

8
A-4. INSTALLING LOCK HOUSINGS
1. Insert the slotted end of the square spindle
into the outside lever hub until it locks, at an
angle of 45º. (The spindle can be removed
by pulling on it, if oriented incorrectly.)
2. Assemble gasket onto the outside
housing (a). Assemble cylindrical plate
assembly onto the outside lock hous-
ing. (Not required for PowerStar ver-
sions)
3. Place the outside housing (a) and
cylindrical plate assembly on the
door so that it engages the latch as
shown.
4.
On the inside trim assembly, turn the
lever to the correct horizontal rest
position for the handing of the door. Install the
tension spring (l) between
the stop plate (h) and the post (p).
Square Spindle Position
correct incorrect
a
Cylindrical Plate
Assembly
(outside)
cylindrical
unit
latch
h
p
l
Gasket
(not for PowerStar versions

9
A-5. INSTALLING THE STRIKE
Note: Use only the strike and strike box supplied. The
use of non-approved parts will result in a functionality
problem and may void the warranty.
1. Mark location of strike on the door frame, making
certain that the strike opening is aligned with
latch bolt.
2. Mortise doorframe for strike 3⁄32" (3 mm)
deep minimum to dimensions shown. Make
cut out for dust box. Secure strike to the
door frame using two 1" (25 mm)
combination screws.
Caution: Check the operation of the latch by making sure that the deadlatch
stops against the strike 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 P (Installing Rubber Bumpers).
5. Put the thumbturn (T) in a vertical
position. Assemble 3 spacers (S) on
the door (for recent models only).
Place the inside trim assembly on the
door so that the upper and lower
spindles (F) and (G) engage the
thumbturn and the inside lever. Fasten
to the outside housing using the three
1/8" hex drive mounting screws (I).
Install the screws without tightening.
Verify the inside lever and thumbturn
operates smootly. If not move the
inside and outside housings slightly.
Then tighten the screws.

10
B. MORTISE
Checklist and Exploded Views (Mortise Only)
Each E2x00 Mortise lockset includes:
(A) Outside lever handle
(or)
Parts for Mechanical override model only:
(A1) Outside lever handle
(B1) Outside housing
(C1) Cylinder plug
(D1) Cylinder (for locks with KIL option)
(E1) Cylinder cap
(E2) Instruction sheet “How to attach lever on lock”
(B) Outside housing
(C) Battery holder with 3 AA batteries (not for PowerStar versions)
(D) Mortise (ASM only shipped assembled with faceplate and 2 x 8-32 x 1/4”
screws)
(E) Inside trim assembly, details depend on lock model
(E3) Drilling template
(N) Outdoor Gasket (not for PowerStar versions)
Parts inside hardware bag:
(F) Thumbturn (hex) spindle
(G) Square spindle
(H) Phillips screw (6-32X 5/16”) (not for PowerStar versions)
(I) 3 x mounting screws (12-24, 1/8” Hex Head)
(J) 2 Machined screws (12-24X 1/2” Philips) & 2 wood screws (#12 X 1” Philips)
(K) Strike kit (screws, strike and dustbox)
(L) 1 extension spring
(R2) 1 Cylinder with 2 keys for E2x00 with override
(S) 3 spacers for recent Models only
(T) Allen Key 1/8”
(U) Allen Key 5/64”

11
Tools Required:
• Safety Glasses
• 1/2 (13mm) chisel
• 1/8 (3mm) drill bit
• 1/2” (13mm) drill bit
• 1” (25mm) drill bit or hole saw
• Drill
• Awl or center punch
• Hammer Rubber mallet
• Small flat screwdriver
• Philips screwdriver (#2)
• Fine steel file
• Mortising machine
• Router
• Mortise faceplate router template
• Adjustable square
• Tape measure
• Pencil
• Tape
• Cleaning supplies (drop cloth, vacuum)

12
American Standard Mortise illustrated
A
C
H
B
N
F
D
S
G
J
J
L
I
E
K
B1
D1
C1
A1
E1

13
B-1. Installation of Standard ASM Models
1. Check the Mortise Handing
a. Compare the mortise with the diagram below. If the mortise is the
correct handing for the door, continue with step 2.
Note: Refer to B-2 to change the handing of a field-reversable mortise.

14
2. Install the Strike
a. 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.
Note: Respect applicable building codes regarding handle height.
b. Mark the locations of the dust box cutout and mounting screws for the
strike.
c. Mortise the door frame to receive the dust box, and drill the pilot holes
for the mounting screws (dimensions and depths marked on template).
d. Position the strike against the doorframe and align it with the
mounting screw holes. Trace the outline of the strike.
(CL)

15
e. Remove material from within the strike outline so that the strike will
be flush with the doorframes.
f. 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 machined screws for steel frames.
Note: 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 supplied. Use of non-approved parts may void the warranty.

16
B-2. Reversing the Mortise Handing
1. Reversible ASM
a. Remove the mortise faceplate. Place the mortise on a flat surface
for the following steps.
b. Partially extend the deadbolt:
For normal ASM, rotate hub (H) using a screwdriver, until the deadbolt
(D) extends approximately 1/4”.
Proceed to step c.
1/4”
H
D

17
For Autodeadbolt ASM, rotate hub (H) until the deadbolt (D) is fully
retracted. The deadbolt will extend approx. 1/16” from the mortise case.
Hold deadbolt (D) gently. Press and release the auxiliary latch (X). You should
feel the deadbolt trigger and begin to extend under the force of the spring.
Release the deadbolt (D) gently. It should extend to 5/16” approx. and stop. If
the deadbolt extends past this point, gently press it in until it locks at 5/16”
throw, or start step b again.
D (hold gently)
X (press and release)
D
5/16”
D
1/16”
H

18
1. Reversible ASM (continued)
c. Push in the latch bolt (L) to the middle of its stroke, and hold it there.
(Continue Step 1 and 2)
Hold the latch (L) inside the mortise, and insert the tailpiece retaining
tool (S, part #027-510382 or #041-513342 available separately) so that
the tailpiece (T) will not drop inside the mortise case. Hold the tool and
the latch with one hand, and slide up the tailpiece using a small screwdriver.
Continue to hold tool (S). Release the latch bolt (L) and keep the anti-
friction latch (F) toward the flat side of the latch bolt so that the bolt
extends fully.
12
Use a small screwdriver
to lift unlock mechanism.
Unlock PositionLock Position
Push in the latchbolt to the
end of the stroke, and hold
it there.
LL
L
T
S
(part #027-510382)
L
F
S

19
d. Pull out the latch bolt (L), until it just clears the front plate. (Note: If
you remove the bolt completely, you must turn it 90° to re-insert it.)
Rotate the latch bolt (L) 180°. Re-insert it to the end of its stroke.
Holding tool (S) in place, re-engage tailpiece (T) with latch bolt (L)
(slide tailpiece down). There may be some play required to align the
parts. Remove the tool (S).
Release the latch to the middle of the stroke and hold it there. Use a
small screwdriver to push the lock mechanism back on lock position
(see step 1 and 2) .
Note: The lock mechanism has to be horizontal on lock position
L
180°
L
L
T
S

20
f. The mortise should look like the diagram below. (Check the orientation
of the latch bolt and auxiliary latch.) Check the bevel of the mortise and
change it if required as described in section B-4, paragraph 6.
For LH (left hand) and RHR
(right hand reverse)
For RH (right hand) and
LHR (left hand reverse)
ASM
W
V
W
V
Only apply to mortise no deadbolt,
auto-deadbolt and armed automatic deadbolt
e. Release the latch bolt (L). Position the latch bolt so that the bottom
tooth of the anti-friction latch (F) remains inside the mortise case as
shown.
Note: If the tooth of (F) is outside the mortise, you will not be able to re-
assemble the faceplate on the mortise.
L
F
L
F (tooth)
mortise
bottom view