Kaba E-PLEX User manual

E-PLEX
11/4” MORTISE INSTALLATION INSTRUCTIONS
®

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TABLE OF CONTENTS
Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Exploded Install Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
A. Mortise anding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
B. Door Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
C. Installing the Strike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
D. Installing Outside Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
E. Installing Inside Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
F. Installing the Inside Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
G. Changing Key-In-Lever Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
. Installing / Removing Outside Lever (Key-In-Lever) KIL . . . . . . . . . . . . . . . . . . . . . . . . .18
I. Installing / Removing Outside Lever (Interchangeable/ . . . . . . . . . . . . . . . . . . . . . . . . .18
removable core models)
J. Installing the Battery Pack and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
K. Testing the Operation of the Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
L. Programming and Software Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
M. Installing Rubber Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Warning:The Ma ter Code of thi lock ha been factory pre et:
1,2,3,4,5,6,7,8. To activate lock function , the ma ter combination
mu t be changed at time of in tallation.
Warnings and Cautions
mportant: Carefully inspect windows, door frame, door, lights, etc.
to ensure that the recommended procedures will not cause damage.
Kaba Access Control’s warranty does not cover damages caused by
installation.
Caution: Wear safety glasses when preparing door.

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ntroduction
The purpose of this manual is to instruct the installer on the proper installation
procedure for the E-Plex 5x66 and 5x67 1 1⁄4" American Steel Mortise (ASM)
Mortise locks. These instructions pertain to models with and without deadbolts.
For models without deadbolts, please disregard any references to a thumbturn
in the instructions.
TOOLS REQU RED
• Safety glasses
• 1⁄2" (13 mm) chisel
• 1⁄8" (3 mm) drill bit
• 1⁄4" (7 mm) drill bit
• 1⁄2" (13 mm) drill bit
• 21⁄8" (54 mm) hole saw
• Drill
• Awl or center punch
• ammer
• Small flat screwdriver
• Phillips screwdriver (#2)
• Fine steel file
• Mortising machine
• Router
• Mortise faceplate router
template
• Adjustable square
• Tape measure
• Pencil
• Tape
• Cleaning supplies
(drop cloth, vacuum)
OPERAT ONAL NOTE:
The E-Plex Mortise lock is almost identical to the E-Plex 5000
Cylindrical lock with the following exceptions:
1. Operation of the Lever When the lock’s handing is properly
set, only a downward rotation of lever will actuate latch.
2. Key Override Use The key override differs in that rotating
the key does not actuate the latch. To use the key override
the key must be inserted into the cylinder and rotated count-
er clockwise until it stops (approximately 90 degrees) then
while holding the key in this position with one hand use the
other hand to rotate the lever downward to retract the latch.
Once the lever has rotated a few degrees the key may be
released.

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For technical assistance please call
1-800-849-TEC (8324) or 336-725-1331
The 1 1⁄4" Mortise lock for the E-Plex series comes preassembled from the
factory for a left-hand installation. It is field reversible.
nstallation Qualifications
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 Access Control is not responsible for
damage, injury or malfunction due to incorrect installation.
Outside Unit
Assembly
Outside Lever
Assembly
Mounting
Plate
Mortise Lock
Mortise Faceplate
Strike
Mortise
Spindle
Thumbturn
Spindle
Lower
Mounting
Screws Release
Tool
Mounting
Plate
Screws
Allen
Wrench
Battery Cover
Screws
Battery Pack Cover
Battery Pack
Lectrobolt
Inside Unit
Assembly
Inside Lever
Security
Screw Tool
Upper
Mounting Screw
E-PLEX 11⁄4" Mortise Lock
5x66 and 5x67

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A. MORT SE HAND NG
Compare the mortise with the figure. If the mortise is the correct handing for
the door, you may skip the next section on reversing the Mortise anding.
A. 1.1 REVERS BLE ASM
A-1.1
1. Remove the mortise faceplate.
Place the mortise on a flat
surface for the following steps.
2. Partially extend the deadbolt:
For normal ASM, rotate hub ( ) using a
screwdriver, until the deadbolt (D)
extends approximately 1/4”.
For LH (left hand) and
RHR (right hand reverse)
For RH (right hand) and
LHR (left hand reverse)

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A-1.1 Continued
3. Push in the latch bolt (L) to the
middle of its stroke, and hold it
there. (Continue Step 1 and 2)
old the latch (L) inside the mortise, and insert the tail-
piece retaining tool (S) so that the tailpiece (T) will not
drop inside the mortise case. old 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.
4. Pull out the latch bolt (L), until it just clears the front
plate.
NOTE: If you remove the bolt completely, you must turn
it 90oto re-insert it.)
Rotate the latch bolt (L) 180o. Re-insert it to the end of
its stroke.
olding tool (S) in place, re-engage tailpiece bolt (L)
(slide tailpiece down). There may be some play required
to align the parts. Remove the tool (S).
Lock Pos t on
180o
Unlock Pos t on

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).
MPORTANT: The lock mechanism has to be
horizontal on lock position.
5. 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.
MPORTANT: f the tooth of (F) is outside the mortise, you will not be
able to re-assemble the faceplate on the mortise.
6. f the auxiliary latch (X) is
shaped like a triangle, there is
no need to change its handing.
f the auxiliary latch (X) is
crescent shape, remove it,
turn it 180o, and replace it. The
auxiliary latch slides easily in and
out of the mortise.
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F (tooth)
mort se
bottom v ew
X (tr angular = OK)
X (crescent = must be reversed)
(re- nsert)
180o

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7. The mortise should look like the diagram
at the right. (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-8 on
page 14.
B. DOOR PREPARAT ON
If using the installation jig to prepare the door, refer
to the instructions provided with the jig, then proceed
with step 7.
B-1 Mark the handle height on the edge of the door,
as determined directly from the strike.
1
1⁄4"
Door
(CL)
Lever Centerline=
Bottom Edge of Strike lip
For LH (left hand) and RHR
(r ght hand reverse)
For RH (r ght hand) and
LHR (left hand reverse)

The axis of rotation of the handle is level
with the bottom lip of the strike.
B-2 Align the template along the vertical
center line of the mortise (CL) at the
desired handle height, and tape it to
the door.
B-3 Mark all holes and cutouts for the
mortise in the edge of the door and
remove the template.
B-4 Locate the two sets of vertical fold
lines on the template allowing you
to adjust the positioning of the tem-
plate depending on the bevel of the
door.
Note: Fold lines on template are for
13⁄4"door. Some thickness and bevel
conditions may make it necessary to
re-position the template for marking
each side of the door.
B-5 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 3° bevel, fold and align the
dashed line marked “ ” 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.”
B-6 Prepare the cutout for the mortise in the edge of the door using a mortis-
ing machine, router and chisel (for dimensions, refer to template). Ensure
clearance is provided for
moving latch parts as
indicated on the tem-
plate.
B-7 When making holes, drill
from both sides of the
door to prevent unsightly
damage (for dimensions,
refer to template). Drill
the small holes before
the large holes. This will
keep small holes on loca-
tion before the 21⁄8" holes
are made tangent with
them.
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Mortise
R /L R (ASM shown) L /R R
P
Logo
Q
R
R

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 condi-
tion, express or implied, including without limitation merchantability, fitness for
purpose 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
warranty 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 mer-
chandise 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 S MPLEX®/E-PLEX®5x00 SER ES
L M TED WARRANTY
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