Kaba Simplex 506 Series User manual

Simplex®506x Mortise
Installation Instructions
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TABLE OF CONTENTS
Tools Required .......................................................................................................................................3
Exploded Install Parts...........................................................................................................................4
A. Mortise Handing.............................................................................................................................5
B. Door Preparation ...........................................................................................................................8
C. Installing the Strike ..................................................................................................................... 10
D. Installing Outside Unit Assembly...............................................................................................11
E. Installing Inside Unit Assembly ..................................................................................................11
F. Installing the Inside Lever ........................................................................................................ 16
G. Changing Key-In-Lever Cylinder ...............................................................................................17
H. Installing / Removing Outside Lever (Key-In-Lever) KIL................................................... 18
I. Installing / Removing Outside Lever (Interchangeable/ ................................................... 18
removable core models)
J. Testing the Operation of the Lock ...........................................................................................21
K. Changing Combinations ..............................................................................................................21
L. How To Reset Lost or Unknown Combination ..................................................................... 23
M. Installing Rubber Bumpers ....................................................................................................... 26
M. Troubleshooting........................................................................................................................... 26
Warning: The combination of this lock has been factory preset, 2 & 4 depressed
at the same time, then 3 and then ENTER. For your security, the combination
must be changed at time of installation.
Warnings and Cautions
Important: 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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Introduction
The purpose of this manual is to instruct the installer on the proper installation
procedure for the Simplex 506x American Steel Mortise (ASM) 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 REQUIRED
 •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
 •2
1⁄8” (54 mm) hole saw
 •Drill
 •Awlorcenterpunch
 •Hammer
 •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)
OPERATIONAL NOTE:
The Simplex Mortise lock is almost identical to the Simplex 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 counter 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-TECH (8324) or 336-725-1331
The 1 1⁄4” Mortise lock for the Simplex series comes preassembled from the
factory for a left-hand installation. It is field reversible.
Installation 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
Deadbolt
Thumbturn
Spindle
Bottom
Mounting
Screws Release/Combination
Change Tool
Inside
Mounting
Plate
Screws
Allen
Wrench
Inside Unit
Assembly
Inside Lever
Top
Mounting Screws
Simplex 11⁄4” Mortise Lock
506x Models
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DOOR HANDING
Some locks also require you to specify door handing. To determine handing,
face the door from the exterior (access) side and select the corresponding dia-
gram below.
A. MORTISE HANDING
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 Handing.
A. 1.1 REVERSIBLE 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 (H) 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)
D
H
1⁄4”
Some locks also require you to specify door handing. To determine handing, face the door from the exterior (access) side and
select the corresponding diagram below.
Inside Inside Inside Inside
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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
to the right)
Hold 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. 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.
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 90o to re-insert it.
Rotate the latch bolt (L) 180o. Re-insert it to the end of
its stroke.
Holding 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 Position Unlock Position
1 2Clip Clip
L
T
S
L
F
S
L
180°
L
L
T
S
L
T
S
L
F
S
L
180°
L
L
T
S
L
T
S
L
F
S
L
180°
L
L
T
S
L
T
S
L
F
S
L
180°
L
L
T
S
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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).
IMPORTANT: 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.
IMPORTANT: If the tooth of (F) is outside the mortise, you will not be
able to re-assemble the faceplate on the mortise.
6. If the auxiliary latch (X) is
shaped like a triangle, there is
no need to change its handing.
If 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.
L
T
S
L
F
S
L
180°
L
L
T
S
L
F
L
F (tooth)
mortise
bottom view
X (triangular = OK)
X (crescent = must be reversed)
180°
(re-insert)
ASM
L
F
L
F (tooth)
mortise
bottom view
X (triangular = OK)
X (crescent = must be reversed)
180°
(re-insert)
ASM
L
F
L
F (tooth)
mortise
bottom view
X (triangular = OK)
X (crescent = must be reversed)
180°
(re-insert)
ASM
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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 PREPARATION
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
Handle
Height
L
F
L
F (tooth)
mortise
bottom view
X (triangular = OK)
X (crescent = must be reversed)
180°
(re-insert)
ASM
For LH (left hand) and RHR
(right hand reverse)
For RH (right hand) and
LHR (left hand reverse)
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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 “H” 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 template.
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 location
before the 21⁄8“holes are made tangent with them.
Mortise
RH/LHR (ASM shown) LH/RHR
Handle
Height
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B-8 Check the bevel of the mortise
faceplate.Ifadjustmentisrequired,
loosen the two bevel screws and
adjustmortisefrontplateangleto
match the bevel of the door (R).
B-9 Re-tighten screws.
B-10 Install the mortise with two 1“
Phillips screws provided (Q).
B-11 Install mortise faceplate with the
two 8-32 x 1 ⁄4“screws provided (P).
C. INSTALLING THE STRIKE
C-1 Align the paper template on the door
frame to match with the desired handle
height, and along the vertical center line of
the mortise (CL), which is also the center line
of the door, allowing for any bumpers on the
door frame.
Respect applicable building codes
regarding handle height.
C-2 Select the strike for the desired handing,
according to the depiction on the template.
Mark the location of the strike cutout and
mounting screws.
C-3 Drill pilot holes for the strike mounting
screws. Mortise the door frame for the
strike dimensions shown.
33 ⁄8“ (L) X 1” (D) X 1” (W)
Note: Make certain not to mortise
over screw holes drilled earlier.
( CL)
Strike
Cutout
P
P
Logo
Q
Q
R
R
Handle
Height
3 3⁄8”
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C-4 Position the strike against the door frame and
align it with the mounting screw holes. Then
mark the outline of the strike.
C-5 Remove any material from within the strike
outline (a) so that the strike will be flush with
the door frame.
C-6 Install the strike using the screws
provided.
D. INSTALLING OUTSIDE UNIT ASSEMBLY
D-1 For door thickness of 13 ⁄4“– 2”, insert the
short square spindle (G) into the outside
housing hub. Door thickness of 21⁄8“– 21 ⁄4“,
insert the long square spindle into the
outside unit hub.
D-2 If your lock comes with a deadbolt
thumbturn, insert the end of the
thumbturn spindle (F) into the small
spindle hole in the outside housing.
Note: Spindle will snap into place or detent
into proper position.
D-3 Place the outside housing on the door so that the bottom spindle engages
the hub on the mortise, and the top thumbturn spindle passes through
the mortise top hub if applicable. The outside unit assembly (C) will rest
flush against the door.
E. INSTALLING INSIDE UNIT ASSEMBLY
Note: Installing levers to the unit assemblies before
mounting the unit assemblies (see setion F) may ease
initial installation.
E-1 Place inside mounting plate flush against the door as
shown. For door thicknesses 13 ⁄4“– 2“insert diagonally
(as shown) two 21 ⁄16 “Phillips flat head screws (supplied
in STD door kit). For door thickness 2”– 21 ⁄4“insert
diagonally (as shown) two 23 ⁄8“Phillips flat
head screws (supplied in thick door kit).
Note: The screws must correspond to the two
through holes in the mortise.
a
G
C
F
F
Inside
Plate
Mounting
Screws
Inside
Mounting
Plate
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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 sub-
ject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 indi-
cated.
* 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
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NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
KABA ACCESS CONTROL 2941 INDIANA AVENUE WINSTON-SALEM, NC 27199-3770
BUSINESS REPLY MAIL
POSTAGE WILL BE PAID BY ADDRESSEE
FIRST-CLASS MAIL PERMIT NO. 1563 WINSTON-SALEM, NC
ALIGN
WITH
UPPER
RIGHT
CORNER
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Thank you for purchasing our product. In order to protect your investment and to enable us to better serve you in the future, please fill out this registration card and return it to Kaba Access Control, or register online at www.kabaaccess.com.
This lock will be used in what type of facility? o Commercial Building o Industrial / Manufacturing o Airport o College / University o Government /Military o School /Educational o Hospital / Healthcare o Other (please specify) What area is being secured with this lock? (e.g. Front Door, Common Door, Exercise Room) This lock is: o New Installation o Replacing a conventional keyed lock o Replacing a Kaba Mechanical Pushbutton Lock o Replacing a Kaba Electronic Access Control o Replacing a Keyless Lock other than Kaba How did you learn about Kaba Access Control Pushbutton Locks? o Advertisement o Previous Use o Internet / Web o Another Use o Locksmith o Maintenance o Training Class o Other (please specify) What was your reason for buying this lock? Who installed your lock? o Locksmith o Maintenance o Other o Check here if you would like more information on Kaba Access Control locks.
Name Position Company Address City State ZIP (Postal Code) Country Phone Email Name of Dealer Purchased From Date of Purchase Lock Model Number
REGISTRATION CARD
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Notes
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E-2 If the lock comes with a thumbturn for
passage (B), insert the thumbturn through the
inside housing (C) and secure using the spring clip (D).
Note: The tailpiece of the passage actuator (A) is
scored on several places to allow you to easily break
off the section that extends beyond the required
length to engage the passage set cam.
E-3 Hold the tailpiece (A) firmly with a pair of pliers,
adjacenttothedesiredbreakline.Withasecond
pair of pliers, grip the tailpiece on the other side
of the scored line and bend up and down until it
breaks.
E-4 For door thickness of 13 ⁄4“– 2”, insert the short
square spindle (G) into the inside housing hub.
Door thickness of 21⁄8“– 21⁄4“, insert the long
square spindle into the inside unit hub.
E-5 Put the deadbolt thumbturn (T), if applicable
in a vertical position and place the inside trim
assembly on the door so that the upper spindle
(F) engages the thumbturn and mortise hubs,
respectively. Carefully push the inside housing
flush against the door.
Door
Thickness
Inside Mounting
Plate Screws
Top Mounting
Screw
Bottom
Mounting Screws
13 ⁄
4” to 2”
(44 mm to 51 mm)
17 ⁄8”
(48 mm)
27 ⁄8”
(73 mm)
5
⁄8”
(16 mm)
21 ⁄8” to 21⁄
4”
(54 mm to 57 mm)
23 ⁄
8
”
(59 mm)
31⁄
4”
(83 mm)
5
⁄8”
(16 mm)
E-6 Insert and tighten the top and bottom mounting screws.
(Refer to the chart above for correct screw lengths.)
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
Insert the inside lever (A) onto the inside unit
assembly. Secure the inside lever with the hex
screw (B) (supplied) using the allen wrench (C)
(supplied).
F
G
T
A
CB
C
B
A
D
Top Mounting
Screws
Bottom
Mounting
Screws
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G. CHANGING KEY-IN-LEVER (KIL) CYLINDER
The Simplex 5000 outside lever comes preassembled
with Kaba’s key-in-lever cylinder (Kaba 1599).
To use a different key-in-lever cylinder
follow remaining steps in this section.
G-1 Remove KIL cylinder (a) from the outside
lever (b) by removing the lever insert (e)
and the cylinder retainer (c) using a
small flat blade screw driver or small
needle nose pliers. Remove the cylinder,
then the tailpiece.
G-2 Determine the proper tailpiece (d) from the
chart below for your KIL cylinder.
You must use a Kaba tailpiece.
The K 2 tailpiece is preassembled with the Kaba 1599.
G-3 Assemble the required tailpiece (d) (supplied with your KIL cylinder).
All tailpieces must be installed vertically for proper
installation, as shown.
G-4 Insert the KIL cylinder into the outside lever
(b) and secure it with the cylinder retainer (c)
and cylinder insert (e) until the KIL cylinder is
snug and unable to move freely.
a
b
c
e
d
f
Assa 65611, Australian: Kaba experT 107K5 &
Boyd KC286, Corbin Russwin 2000-03, Kaba
1599, Schlage 23-001, Schlage Primu 20-760,
Kaba Peaks 1099
Medeco 20W200H1
Arrow C100, Sargent 10 LINE
Marks
Abloy 5277, Abloy 5477, Assa 65691,
Kaba 1539, Kaba Gemini 4730
KIL CYLINDERTAILPIECE
K1
K2
K3
K4
K5
b
a
c
e
d
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H. INSTALLING / REMOVING
OUTSIDE LEVER
(Key-In-Lever models only)(For interchangeable
and removable cores proceed to section I)
Note: Installing levers 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).
Position the lever sleeve (f) tab correctly with the
respective notch on the lever. The lock comes
shipped with the lever sleeve already installed in
the lock housing. When installing lever, ensure
it is oriented to engage the lever sleeve to
accommodate desired lock handing as shown.
H-2 Insert one of the (supplied) keys (a) into the
outside lever (b) and rotate key counterclockwise
45 degrees. If needed, wiggle the lever up and
down while turning the key to lock onto the lever
H-3 Insert the outside lever (b) until it is flush to the
outside unit assembly. Secure the outside lever
by rotating the key clockwise 45 degrees to
horizontal position. Remove key.
Note: To remove the outside lever from the
outside unit assembly, follow the steps below.
H-4 Insert one of the (supplied) keys (a) into the
outside lever (b) and rotate it counterclockwise
45 degrees. Insert release tool (d) into the small
hole (e) under lever as shown. Gently push lever
catch up until it clicks. Remove tool, then remove
outside lever (b).
I. INSTALLING / REMOVING OUTSIDE LEVER
(Interchangeable / Removable Core Models)
Note: Installing lever to the unit assemblies
before mounting the unit assemblies may
ease initial installation.
I-1 Make certain the lever catch is up as shown (c).
Position the lever sleeve (f) tab correctly with the
respective notch on the lever. The lock comes
LH
KIL Lever Sleeve
RH
f
c
Correct
Position
Incorrect
Position
b
a
45º
a
b
d
e
c
Correct
Position
Incorrect
Position
RH
LH
IC Lever Sleeve
f
f
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19
shipped with the lever sleeve already installed in
the lock housing. When installing the lever,
ensure it is oriented to engage the lever sleeve to
accommodate desired lock handing as shown.
I-2 Insert the outside lever (b) until it is flush to the
outside unit assembly (a). To secure the outside
lever, insert the release tool (d) (or screw driver)
into the outside lever as shown, and slide the lever
catch down until it clicks. Make certain lever is
attached before installing the core.
Note: For all interchangeable/removable cores
except ASSA/Medeco/Yale, proceed to section I-3.
For ASSA/Medeco/Yale cores, skip to section I-5.
I-3 Insert the supplied tailpiece (e) vertically into the
outside lever (b) as shown. Make certain that you
rotate the tailpiece so that it will align with the
interchangeable core. For screw cap type cores
(Schlage) (g), the tailpiece must be assembled
to the core first (vertical position). Insert the
interchangeable core into the outside lever.
Note: To remove the outside lever from the
outside unit assembly, follow the 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.
Insert the release tool (d) into the small hole (f)
under lever as shown. Gently push lever catch up
until it clicks. Remove tool, then remove outside
lever (b).
d
a
b
b
e
g
vertical
a
f
d
b
g
e
vertical
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I-5 For ASSA/Medeco/Yale interchangeable/removable cores, the tailpiece
must be prepped for the desired length before installation.
I-6 Notice the score marks on the flat portion
of the ASSA/Medeco/Yale tailpiece. Using
the diagram to the right, locate the score
mark on your tailpiece that matches your
core prep for the intended application,
and break the tailpiece off accordingly.
Note: 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-7 Insert the ASSA/Medeco/Yale 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 core. Insert the
interchangeable/removable core into the
outside lever.
Note: To remove the outside lever from the
outside unit assembly, follow steps below.
I-8 Remove the interchangeable/removable core.
Then remove the tailpiece (e).
Note: You may want to use needle nose
pliers for some tailpieces.
I-9 Insert the lever release tool (d) into the small hole
(f) under lever as shown. Gently push lever catch
up until it clicks. Remove tool, then remove outside
lever (b).
YALE 6 & 7 PIN,
CYLINDRICAL – THIN DOOR
(1 3⁄8” (35 mm) to 1 1⁄2” (38 mm))
(DO NOT SHORTEN TAILPIECE -
For 1 5⁄8” (41 mm) to 2 1⁄4” (57 mm))
ASSA/MEDECO 5, 6 & 7 PIN,
CYLINDRICAL – DO NOT
SHORTEN TAILPIECE
ASSA & MEDECO 6 PIN,
EXIT & MORTISE
MEDECO 5 PIN,
EXIT & MORTISE
YALE 6 & 7 PIN,
EXIT & MORTISE
a
g
vertical
b
e
f
d
b
g
e
vertical
LIT1051_Simplex_506x _Mortise_1012.indd 20 1/7/13 3:13 PM