Kaba 7102 series User manual

English
Installation Instructions
Pushbutton Lock
PK2387
7102
7108
SERIES

Please keep these instructions. The combina-
tion of this lock has been factory preset:
2 and 4 pressed together, then 3.
WARNING
For your own safety, you must change the
combination at the time of installation.
PLEASE READ AND FOLLOW ALL
DIRECTIONS CAREFULLY
Since every installation is unique, carefully
check windows, frame, door, etc. to ensure that
the recommended procedures will not cause
damage. KABA ILCO is not responsible for
any damage caused by installation.
Tools Required
• 1⁄4" (6 mm) Drill Bit
• 1" (25 mm) Wood Chisel
• 3⁄4" (19 mm) Hole Saw
• Phillips-head Screwdriver
• 1" (25 mm) Drill Bit or Hole Saw
• 15⁄8" (41 mm) Hole Saw
• 2 Pairs of Pliers
• Hacksaw
• Hammer
• Center Punch
• Drill (variable speed)
2

Table of Contents
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Determining the Lock Location . . . . . . . . . .5
Marking the Door . . . . . . . . . . . . . . . . . . . . .5
Drilling Holes in the Door . . . . . . . . . . . . . .6
Making the Bolt Face Plate Cutout . . . . . . .7
Installing the Bolt . . . . . . . . . . . . . . . . . . . . .7
Adjusting the Lock . . . . . . . . . . . . . . . . . . . .8
Installing the Lock . . . . . . . . . . . . . . . . . .9-10
Checking the Lock’s Operation . . . . . . .10-12
Installing the Strike . . . . . . . . . . . . . . . . . . .12
Setting a New Combination . . . . . . . . . .13-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . .15
3

4
Checklist
Use this checklist to make sure that
everything has been included.
qA - Front Lock
qC - Dead Bolt (7102-23⁄4", 7108-23⁄8")
qD -Inside Thumbturn Assembly
qE - Inside Combination Change Assembly
qF - Strike Plate
Screw Pack:
qG -4 thru-bolts (3")
qH - 2 (bolt) combination
wood/metal screws
qI - 4 combination wood/metal screws
qJ - 4 Thru bolts (23⁄8")
Templates (in center of booklet)
Determine the hand
of your door
Many of the installation instructions refer
to the handing of your door. The hand of the
door is determined with the door in the
closed position, from the exterior or
pushbutton side of the door .
A) Right Hand Door. Door opens inward
(push). Hinged on the right side.
B) Left Hand Door. Door opens inward
(push). Hinged on the left side.
C) Right Hand Reverse Door. Door opens
outward (pull). Hinged on the right side.
D) Left Hand Reverse Door. Door opens out
ward (pull). Hinged on the left side.
AE
D
C
F
G
H
I
23/8 "
3"
J
LH - Left Hand
RH - Right Hand
LHR - Left Hand Reverse
RHR - Right Hand Reverse
A
B
C
D

2-1.
1-1.
5
2
14"
*
7"
Determining the
Lock Location
Marking the Door
NOTE: Be sure to use the correct
template (right-hand or left-hand
door - 23⁄8" or 23⁄4" ).
1) Carefully fold the template on 23⁄8" or 23⁄4"
line (found in the center of this booklet) as
indicated in figure 2-1.
2) Tape the template securely to the outside
of the door so that all the indicated
folds are properly aligned with the
edge of the door.
3) Use a center punch to make the marks for
drilling the seven holes precisely at the
points indicated on the template. The
center punch mark in the edge of the
door must be centered based on the
thickness of the door.
4) Remove the template.
Install the lock with the exterior thumbturn
hole at least 7" (18 cm) above your primary
lockset so it is comfortable to operate and not
in the way when you turn the door knob.
*A minimum stile width of 4" (10.16 cm) is
required for mounting, figure 1-1.

3-2.
3-1.
6
D
4" (10 cm)
3
A
C
D
B
1/4"
1"
3/4"
Drilling Holes in the Door
CAUTION: Positioning and drilling must be
done straight to ensure trouble free operation
of the 7100 Series lockset. Improper drilling
may result in excessive force being exerted
on the lock which may result in the
premature wearing of its mechanical parts.
You must do Step 1 first otherwise
it will be impossible to drill the
1⁄4" (6 mm) holes.
1) Use a 1⁄4" (6 mm) drill bit to drill the four
holes marked A, figure 3-1.
Begin drilling at a slow speed and increase
the speed gradually until the tip of the drill
bit emerges from the other side of the door.
Repeat this procedure from the opposite side
of the door. This technique will prevent splin-
tering of the door or breaking the drill bit.
2) Use a hole saw with pilot bit to make
the 15⁄8" (41 mm) hole (B). Apply pressure
evenly until the circular blade cuts the first
side of the door and the tip of the pilot bit
emerges through the other side, then stop.
Drill from the other side until the
15⁄8" (41 mm) hole is completed.
3) Repeat Step #2 for the
3⁄4" (19 mm) hole, (C).
4) The final 1" (25 mm) hole (D) is cross-
bored through the edge of the door.
Carefully bore 4" (10 cm) deep,
1⁄4figures 3-1 & 3-2.

5-1.
4-1.
7
4
AB
5
5-2.
Making the Bolt Face
Plate Cutout
Installing the Bolt
RIGHT HAND DOOR
(see template)
1) Insert the bolt, with the arrow pointing
up, into the 1" (25 mm) hole, figure 5-1.
2) Secure the bolt face plate to the
door with the two Phillips-head
screws provided.
LEFT HAND DOOR
(see template)
1) Insert the bolt, with the arrow
pointing down, into the 1" (25 mm)
hole , figure 5-2.
2) Secure the bolt face plate to the door with
the two Phillips-head screws provided
(pg.7, H).
This procedure is applicable to wood doors.
1) Insert the bolt into the 1" (25 mm) hole
until the face plate butts up against the
door edge. Draw a line around the face
plate. Remove the bolt from the door,
figure 4-1,A.
2) For doors without a beveled edge, use a
sharp 1" (25 mm) wood chisel to remove
approximately 1⁄8" (3 mm) of material or
enough so the face plate is perfectly flush
with the edge of the door, figure 4-1, B.
3) For doors with a beveled edge, follow
Step 2 except the face plate will not be
flush with the edge of the door, but rather
square to the face of the door. In order to
accomplish this, you must remove more
wood from the higher edge of the door.

8
6
6-1.
6-2.
Adjusting the Lock
The lock has been pre-assembled to
accommodate doors up to 21⁄4" (57 mm) thick.
If your door is 13⁄8" to 2 " (35 mm to 51 mm)
thick, you must shorten both tailpieces
X& Y, figure 6-1.
1) Shorten the combination change tailpiece
Xaccording to your door thickness.
Tailpiece Xhas been premarked for various
door thicknesses for accuracy and
convenience, figure 6-1.
1a. After determining the breakoff point, hold
the tailpiece firmly with a pair of pliers on
the lock side of the tailpiece, just
beside the desired break line.
1b. With a second pair of pliers, grip the
tailpiece at the other side of the line
and bend it up and down until it breaks,
figure 6-2.
2) While holding the lockset firmly against the
outside surface of the door, figure 6-1, mark
tailpiece Yat the point where it extends
1⁄2- 5⁄8" beyond the interior surface of the
door. Shorten tailpiece Yusing the
procedure described in Steps 1a & 1b.

9
7
X
Y
7-1.
Installing the Lock
• For 13⁄8" - 13⁄4" (35 mm - 44 mm) thick doors,
use the 23⁄8" (44 mm) thru bolts.
• For 2" - 21⁄4" (51 mm - 57 mm) thick doors,
use the 3" (76 mm) thru bolts.
1) With the bolt extended in the locked
position, mount the lock from the outside
of the door. Insert the tailpiece Yinto the
vertical cutout of the bolt assembly and
the tailpiece Xinto the 3⁄4” (19 mm) hole,
figure 7-1.
2) Hold the exterior lock assembly firmly
against the door. Try the factory-set
combination. Press buttons #2 and #4
together, release, press button #3, and
release. A distinctive click must be felt to
indicate that the button has been correctly
depressed. Turn the outside thumbturn to
the right (clockwise) to the stop position
and release (the bolt should be fully retrac-
ted). If not, turn the thumbturn to the left
(counterclockwise) to the stop position
and repeat Step 2.
3) While holding the lock firmly against
the outside surface of the door with one
hand, use the other to mount the inside
thumbturn assembly to the interior side of
the door with two thru-bolts finger tight,
figure 7-2. Make sure that tailpiece Y
is engaged into the vertical cutout of the
inside thumbturn assembly.
4) Insert tailpiece Xinto the horizontal slot of
the combination change assembly, It may be
necessary to use a screwdriver to align tailpiece
Xwith the combination change assembly,
figures 7-2 & 7-3. Once aligned, secure with
two thru-bolts, but do not tighten, figure 7-4.

10
7-4.
8
7-3.
Y
7-2.
Note: The inside thumbturn is shown in
a vertical position to show the two
thru-bolts. It may be assembled either
vertically or horizontally.
IMPORTANT: Tailpiece Xmust be inserted
in the horizontal slot in order to change
your combination.
5) Make sure that both assemblies are
correctly centered over the holes. Tighten
the thru-bolts evenly. Uneven tension could
cause a malfunction of the lock.
Checking the Lock’s
Operation
IMPORTANT: The following steps
MUST be performed while
the door is open.
Note: Turning the outside thumbturn to the
left (counterclockwise) to the stop position
and releasing extends the bolt to the locked
position. To retract the bolt from the outside,
depress the buttons of your preset combina-
tion, then turn the thumbturn to the right
(clockwise) to the stop position.
1) Turn the outside thumbturn to the
left (counterclockwise) until it stops,
then release it.
2) Press the preset factory combination
(2 and 4 pressed together, release, then 3,
and release). A distinctive click must be
felt to indicate that the buttons have
been correctly depressed.
3) Turn the outside thumbturn to the right
(clockwise) until it stops; the bolt should
fully retract, figure 8-1. If the bolt does
not retract, turn the thumbturn to the left
(counterclockwise) until it stops. This will
clear previously depressed buttons.
Release it and repeat Step 2.

11
8-1.
A
B
8-2.
4) Release the outside thumbturn; the bolt
will stay in the retracted position.
5) Turn the inside thumbturn Ato the stop
position; the bolt will extend to its locked
position, figure 8-2.
6) If the bolt does not retract or extend fully,
loosen the two thru-bolts of the inside
thumbturn assembly A, figure 8-2. Move
the inside thumbturn assembly upward or
downward to properly center the inside
thumbturn assembly with the tailpiece,
then tighten the thru-bolts, and repeat
Steps 1 to 5.
7) If the bolt still does not fully retract or
extend after repeating Step 6, loosen the
two thru-bolts of the inside thumbturn
assembly Aand combination change
assembly B. Move the lock upward or
downward to properly align both tailpieces
of the inside thumbturn assembly and
combination change assembly. Tighten the
four thru-bolts and repeat Steps 1 to 5 to
ensure proper operation.
Verify the Combination Change Assembly
1) Insert the tip of a Phillips-head screwdriver
into the combination change assembly B,
figure 8-3.
2) Turn the central piece to the right (clock-
wise) until it stops, DO NOT FORCE,
(approximately 30˚ degrees).
3) Remove the screwdriver; the central
piece should automatically return to its
initial position.
8-3.

12
9-1.
4) If the central piece jams and does not
return to its initial position, loosen the two
thru-bolts and push the combination
change assembly Bupward or downward
to properly center the tailpiece of the com-
bination change assembly, then tighten the
two thru-bolts, and repeat Steps 1 to 3.
4) If the central piece jams and does not
return to its initial position, loosen the two
thru-bolts and push the combination
change assembly Bupward or downward
to properly center the tailpiece of the com-
bination change assembly, then tighten the
two thru-bolts, and repeat Steps 1 to 3.
Installing the Strike
91) Mark the vertical and horizontal center
lines of the strike on the door frame
by using the center line of the bolt.
Make sure the vertical and horizontal
center lines are well aligned with the
bolt center lines.
2) Where the center lines meet, drill a
1" (25 mm) diameter by 11⁄8" (28 mm)
deep hole to guarantee that the bolt
will be completely extended in the
door jamb, figure 9-1.
3) Mortise (chisel out) the marked area to
1⁄8" (3 mm) deep so that the strike will
be flush with the door frame.
4) Secure the strike with the four
screws provided.
5) Close the door and turn the thumbturn to
extend the bolt to ensure proper alignment
with the strike plate hole.

13
10
10-1.
Setting a New
Combination
IMPORTANT: The following steps must
be performed while the door is open.
The factory-set code is 2 and 4 pressed
simultaneously, followed by 3. This code
should be changed as soon as the lock
is installed.
1) Turn the outside thumbturn to the left
(counterclockwise) to the stop position
and return it to the right (clockwise) slowly
to the horizontal position. This will clear
any random buttons previously depressed.
2) Enter the existing code.
3) Insert a Phillips-head screwdriver into
the center of the combination change
sleeve. Gently turn to the right (clockwise)
approximately 1⁄8" (3 mm), figure 10-1.
A slight click should be felt. Do not force.
IMPORTANT: When removing the screw-
driver, the central piece must return to its ini-
tial position, if not, set it back to its original
position using the screwdriver; see Section 9.
Verify the Combination Change Assembly.
4) Turn the outside thumbturn to the left
(counterclockwise) to the stop position,
once only, and slowly return it to the
right (clockwise) to the horizontal
position to clear the existing code
from the mechanism.
5) Select a new code and write it down
(some or all of the buttons may be used
for your new code, pressed individually
or simultaneously).
NOTE:A button may be used only once.
6) With the door open, enter your new code.
Depress each button fully and release.
A slight click should be felt.

14
10-2.
7) Turn the outside thumbturn to the right
(clockwise) to the stop position. The bolt
should retract. Now release the thumb
turn. Try to turn the thumbturn to the right
(clockwise). The thumbturn will not turn
clockwise unless the correct combination
is entered. If it turns and retracts the bolt
without depressing any of the buttons, see
Step 9 below.
NOTE: Excessive force will result in slipping
the thumbturn 180˚ degrees. The slipping
mechanism, or force-proof clutch, protects
the lock’s internal mechanism from
forced entry.
8) If a wrong combination is entered after the
desired combination has been pro
grammed into the lock, turn the outside
thumbturn to the left (counterclockwise)
to the stop position and release,
figure 10-2. This will clear any previously
depressed buttons. Enter the correct new
combination. Turn the thumbturn to the
right (clockwise) to the stop position and
release, figure 11-2. The thumbturn should
rotate. The bolt will be retracted flush with
the face plate. The correct combination
must be entered each time you want to
unlock the door.
9) If, without entering the combination, you
can retract the bolt by turning the outside
thumbturn to the right, it means that
a step was done out of order and therefore
no combination was entered. In this
case, you must repeat Steps 1 to 7 but
omit Step 2, as the lock does not have
a combination.

15
11 Troubleshooting
Lock fails to open when combina-
tion is entered and outside thumb-
turn is rotated clockwise.
Buttons were not fully depressed
when the combination was entered.
Lock not cleared of previous
attempts to enter access codes.
Turn the outside thumbturn to the
left to clear the wrong entry. Enter
the combination making sure you
feel each button click to know that
it was depressed fully.
Turning outside thumbturn clock-
wise always retracts latch without
depressing any buttons.
Lock is in zero combination.
Follow the procedure for setting a
new combination (Section 9,
but omit Step 2).
Inside thumbturn only retracts bolt
partially or not at all, in either clock-
wise or counterclockwise direction.
Bolt was not properly installed.
Remove and re-install the bolt.
Review and follow instructions
in Section 6.
After setting a new combination,
the lock works one time only,
then fails to open.
Buttons of intended combination
were not fully depressed when
changing combination.
This is a lost combination situation.
Please call our Technical Service
Dept. at (800) 849-TECH.
(8324) or [phone]
?
Ô
F
?
Ô
F
?
Ô
F
?
Ô
F

ONE YEAR WARRANTY
This KABA ILCO product is warranted to
be free from defects in material and
workmanship under normal use and
service for a period of one (1) year from
date of purchase. However, this warranty
does not cover problems arising out of
improper installation or use. Our only
liability, whether in tort or in contract,
under this warranty is to repair or
replace products which are returned to
the KABA ILCO factory, shipping charges
prepaid to the address shown within the
one (1) year warranty period.
Our warranty shall only apply if the
item returned is found by analysis by
KABA ILCO factory personnel to be
defective.
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 purpose or absence of latent defects.
KABA ILCO CORP.
2941 Indiana Avenue.,
Winston Salem, NC 27105, U.S.A.
Tel.: [phone] or [phone]
Fax: [phone] or [phone]
www.kaba-ilco.com D8-PKG2387 1204