Kaba Simplex 7104 Series User manual

English
Installation Instructions
Pushbutton Lock
PK782
7104
SERIES

Please keep these instructions.
The combination 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. Ilco Unican 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
• 13⁄8" (35 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 Latch Face Plate Cutout . . . . . .7
Installing the Latch . . . . . . . . . . . . . . . . . . . .7
Adjusting the Lock . . . . . . . . . . . . . . . . . . . .8
Installing the Lock . . . . . . . . . . . . . . . . . .9-10
Checking the Lock’s Operation . . . . . . .10-11
Installing the Strike . . . . . . . . . . . . . . . . . . .12
Setting a New Combination . . . . . . . . .12-14
Troubleshooting . . . . . . . . . . . . . . . . . . . . .15
3

4
Checklist
Use this checklist to make sure that
everything has been included.
qA - Front Lock
qB - Adjustable Latch (7104)
qC - Inside Thumbturn Assembly
qD -Inside Combination Change Assembly
qE - Strike Plate
Screw Pack:
qF - 4 thru-bolts (3”)
qG -4 combination wood/metal screws
qH - 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 opens inward
(push). Hinged on the right side.
B) Left Hand: Door opens inward
(push). Hinged on the left side.
C) Right Hand Reverse: Door opens
outward (pull). Hinged on the right side.
D) Left Hand Reverse: Door opens
outward (pull). Hinged on the left side.
G
A
B
E
3"
23⁄8"
F
H
D
C
LH - Left Hand
RH - Right Hand
LHR - Left Hand Reverse
RHR - Right Hand Reverse
A
B
C
D

5
2
Determining the
Lock Location
Install the lock with the exterior thumbturn
at least 7" (18 cm) above your primary lock
set 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.
Adjusting the Latch
This latch has been secured in the 23⁄4"
back set position with a spring clip. If your
application requires a 23⁄8" back set, remove
the spring clip by utilizing a small screw
driver (or similar) and inserting the tip
through the latch as indicated by the arrow,
and gently pressing on the spring clip until
is removed from the latch.
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
(found in the center of this booklet)
as indicated in figure 3-1.
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 cen-
ter punch mark in the edge of the door
must be centered based on the thickness
of the door.
4) Remove the template.
1
3
3-1.
1-1.
7"
(18 cm)
*4"
2-1.
Spring Clip
Adjustable Latch

Drilling Holes in the
Door
CAUTION: Positioning and drilling must be
done straight to ensure troublefree 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 4-1. 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 splintering of the door or
breaking the drill bit.
2) Use a hole saw with pilot bit to make
the 13⁄8" (35 mm) hole. 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
13⁄8" (35 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,
figures 4-1 & 4-2.
6
4
4-2.
4-1.
D
4" (10 cm)
3⁄4" (19 mm) Hole
1⁄4" (6 mm) Holes A
13⁄8" (35 mm) Hole
D
1"
(25 mm)
Hole
B
C

7
Making the Latch Face
Plate Cutout
This procedure is applicable to wood doors.
1) Insert the latch into the 1" (25 mm) hole
until the face plate butts up against the
door edge. Draw a line around the face
plate, figure 5-1, A. Remove the latch
from the door.
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 5-1, 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.
Installing the Latch
1) For doors that swing outward, the curved
edge of the latch bolt should be facing
inward towards the room. For doors that
swing inward, the curved edge of the
latch bolt should be facing outward away
from the room.
2) Put the latch into the 1" (25 mm) hole,
figure 6-1.
3) Secure the latch face plate to the door
with the two Phillips-head screws
provided, pg.7, H.
5
6
6-1.
5-1.
AB

8
7
7-1.
7-2.
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 7-1.
1) Shorten the combination change tailpiece
Xaccording to your door thickness.
Tailpiece Xhas been premarked for
various door thicknesses for accuracy and
convenience, figure 7-1.
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 7-2.
2) While holding the lockset firmly against
the outside surface of the door, figure 7-1,
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
8
X
Y
8-1.
Y
8-2.
Mount the lock from the outside of the door.
1) Insert the tailpiece Yinto the horizontal
cutout of the latch assembly and the
tail piece Xinto the 3⁄4" (19 mm) hole,
figure 8-1.
2) Hold the exterior lock assembly (pg.7, A)
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
(the lach should be fully retracted).
If not, turn the thumbturn to the left
(counter clockwise) 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 (pg.7, D) to the interior
side of the door with two thru-bolts finger
tight, figure 8-2. Make sure that tailpiece
Yis engaged into the horizontal cutout of the
inside thumbturn assembly.
4) Insert tailpiece Xinto the horizontal slot
of the combination change assembly, (pg.7, E).
It may be necessary to use a screwdriver to
align tailpiece Xwith the combination
change assembly, figures 8-2 & 8-3. Once
aligned, secure with two thru-bolts, but do
not tighten, figure 8-4.
Note: The inside thumbturn is shown
in a vertical position to show the two
thrubolts. It may be assembled either
vertically or horizontally.
Installing the Lock
- For 13⁄8" - 13⁄4" (33 - 44mm) thick doors,
use the 23⁄8" (45mm) thru bolts.
- For 2"- 21⁄4" (51- 57mm) thick doors,
use the 3" (76mm) thru bolts.

10
9
8-4.
8-3.
IMPORTANT: Tailpiece Xmust be inserted
in the horizontal slot in order to change
your combination.
5) Make sure that assemblies Aand Bare
correctly centered over the holes,
figure 8-4.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.
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 latch
should fully retract, figure 9-1. If the
latch does not retract, turn the thumbturn
to the left (counterclockwise) until it stops.
Release it and repeat Step 2.
4) Release the outside thumbturn; the latch
will return to its fully extended position.
5) Turn the inside thumbturn Ain either
direction until it stops; the latch will
retract as in Step 3.
6) Release the inside thumbturn and the
latch will return to its initial fully
extended position.