Knox KLS-4400 User manual

KNOX ELOCK CORE RETROFIT
KLS-4400 & KLS-4500 INSTALLATION GUIDE
Dust Cover Bracket
Dust Cover Magnet
Mechanical Lock Shell
Mechanical Lock Core
Mechanical Key
Dust Cover
Special Release Non-Metallic (Fiber) Washer
Note: Replace if over-tightened or cracked
DO NOT SUBSTITUTE
Lock Shell Nut
90° Stop Washer (See Figure 5)
Adjustment Shim Washer
Cam
Lock Washer
Lock Cam Nut
Aluminum Space Washer (Cover)
Mounting Screw
Lock Mechanism Cover
Dust Cover Bracket
Aluminum Space Washer (Cover)
Mounting Screw
Lock Shell Nut
90° Stop Washer (See Figure 5)
Adjustment Shim Washer
Cam
Lock Washer
Lock Cam Nut
Knox eLock Core
Knox eLock Shell
Dust Cover
Knox Rain Gaurd
Knox eKey
Special Release Non-Metallic (Fiber) Washer
Note: Replace if over-tightened or cracked
DO NOT SUBSTITUTE
Lock Mechanism Cover
CAUTION:
Activate Knox eKey and Knox eLock Core prior to installation! The Knox eLock Core and the Knox eKey must be activated before installation
of the Knox eLock Core. See the KnoxConnect™Management System Administrator User Guide for further instructions.
Figure 2
Knox eLock Core Installation
Figure 1
Mechanical Lock Core Removal
Installation Time:
Less than 15 minutes

1601 W. DEER VALLEY RD. PHOENIX, AZ 85027 | T. 800-552-5669 | F. 623-687-2290 | [e-mail] | KNOXBOX.COM
OPE-ESYSLR-0303-D
©Knox Company. All Rights Reserved
KNOX ELOCK CORE RETROFIT:
KLS-4400 & KLS-4500 INSTALLATION GUIDE
2
MECHANICAL LOCK CORE REMOVAL
Disassemble the Mechanical Lock:
Lift the Dust Cover, insert the key, and
open the lock box, to expose the protective
Lock Mechanism Cover. Turn the key to
"Locked Open" position.
Use a 9/16" socket or wrench to remove
the Lock Cam Nut and Lock Washer.
Push in the Lock Core and remove the
Cam, the remaining Washers, and the
Cam Stop Washer. Set aside for later use.
Use a 7/8" wrench to remove the Lock
Shell Nut from the inside of the door.
Set aside for later use.
Remove the Lock Shell from the outside
of the door.
Remove the Lock Core. Pull out the
Key along with the Lock Core from the
outside of the door.
Remove the two Mounting Screws
holding the protective Lock Mechanism
Cover in place, and remove it.
1
4
7
5 6
2 3
IMPORTANT:
Return Lock Shell with the Lock Core and Mechanical Key to Knox
Company. Contact Technical Support for return instructions.
NOTE:
For illustration of part
disassembly, see rst page.
Removing the Dust Cover Bracket
and Dust Cover:
For older models, you DO NOT need to
remove the Dust Cover Bracket and Dust
Cover if it does not come loose after the
removal of the Lock Shell. (Older model
4400 & 4500 units have a different design
that utilizes four rivets to afx the Dust
Cover Bracket to the Door.)
For newer models, the Dust Cover and
Dust Cover Bracket will come off with the
Mechanical Lock Shell. Set them aside for
reuse with the new Knox eLock Shell.
Dust Cover Bracket
Aluminum Space Washer (Cover)
Mounting Screw
180° Stop Washer (See Figure 5)
Adjustment Shim Washer
Bridge Cam Assembly
Lock Washer
Lock Cam Nut
Knox Rain Guard
Knox eLock Shell
Knox eLock Core
Dust Cover
Knox eKey
Special Release Non-Metallic (Fiber) Washer
Note: Replace if over-tightened or cracked
DO NOT SUBSTITUTE
Lock Mechanism Cover
Lock Shell Nut
Figure 3
Independent Dual Lock Door Assembly

1601 W. DEER VALLEY RD. PHOENIX, AZ 85027 | T. 800-552-5669 | F. 623-687-2290 | [e-mail] | KNOXBOX.COM
OPE-ESYSLR-0303-D
©Knox Company. All Rights Reserved
KNOX ELOCK CORE RETROFIT:
KLS-4400 & KLS-4500 INSTALLATION GUIDE
3
KNOX ELOCK CORE INSTALLATION
Assemble the Knox eLock Core:
Line up the sidebar of the Knox eLock
Core with the groove in the Knox eLock
Shell and slide the Lock Core into the
Lock Shell from the outside of the door.
Slide the new Knox eLock Shell into the
door from the outside and check the
inside to ensure the Cam Stop Washer
tab faces away from the hinge.
Install the Lock Shell Nut onto the Lock
Shell from the inside of the door. Ensure
the TAB on the Lock Shell is oriented to the
right or away from the hinge as you look
at it from the back of the door. Use a 7/8"
wrench to tighten the nut to snug.
31 2
Reinstall the Cam Stop Washer onto
the Lock Core from the inside of the
door as shown. Refer to Figure 5 for Stop
Washer Alignment.
Reinstall the Cam, Lock Washer, and
Lock Cam Nut.
BRACE THE CAM from turning with a
screwdriver, and tighten the Lock Cam Nut
to snug using a 9/16" socket or wrench.
4 5 6
IMPORTANT!
Ensure the Stop Washer is installed in
the position shown in Figure 5. Note
the TAB location.
IMPORTANT!
Do not attempt without the screwdriver
in place. This will prevent damage to the
Knox eLock Core while tightening the nut.
CAUTION:
Activate Knox eKey and Knox eLock Core prior to installation!
The Knox eLock Core and the Knox eKey must be activated
before installation of the Knox eLock Core. See the KnoxConnect™
Management System Administrator User Guide for further instructions.
Figure 5
Stop Washer Alignment
IMPORTANT:
Stop Washer orientation sets the direction that the cylinder
is turned to lock and unlock the Knoxbox.
Single Lock Independent
Dual Lock
Dependent
Dual Lock
90° Stop Washer
Orientation
180° Stop Washer
Orientation
90° Stop Washer
Orientation
Assemble In
Locked Position
Single Lock
90° Stop Washer
Orientation
Assemble In
Locked
Position
Factory Setting:
The door will
unlock when key
is turned
to the LEFT
Dependent
Dual Lock
90° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when BOTH keys
are turned to
the LEFT.
Independent
Dual Lock
180° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when top key is
turned to the RIGHT
OR bottom key is
turned to the LEFT.
TOP
LOCK
BOTTOM
LOCK
TOP
LOCK
BOTTOM
LOCK
Assemble In
Locked Position
Single Lock
90° Stop Washer
Orientation
Assemble In
Locked
Position
Factory Setting:
The door will
unlock when key
is turned
to the LEFT
Dependent
Dual Lock
90° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when BOTH keys
are turned to
the LEFT.
Independent
Dual Lock
180° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when top key is
turned to the RIGHT
OR bottom key is
turned to the LEFT.
TOP
LOCK
BOTTOM
LOCK
TOP
LOCK
BOTTOM
LOCK
Assemble In
Locked Position
Single Lock
90° Stop Washer
Orientation
Assemble In
Locked
Position
Factory Setting:
The door will
unlock when key
is turned
to the LEFT
Dependent
Dual Lock
90° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when BOTH keys
are turned to
the LEFT.
Independent
Dual Lock
180° Stop Washer
Orientation
Assemble In
Locked Position
Factory Setting:
The door will unlock
when top key is
turned to the RIGHT
OR bottom key is
turned to the LEFT.
TOP
LOCK
BOTTOM
LOCK
TOP
LOCK
BOTTOM
LOCK
Factory Setting:
The door will
unlock when key
is turned to the
LEFT.
Factory Setting:
The door will
unlock when top
key is turned to the
RIGHT OR bottom
key is turned to the
LEFT.
Factory Setting:
The door will
unlock when
BOTH keys are
turned to the
LEFT.
Figure 4
Back View of 4400 Door with Lock Mechanism Cover Removed
in the Unlocked Position
Single
Lock Independent
Dual Lock
Re-locking Mechanism
– depress to test proper
action of bolt before
replacing lock cover.
WARNING:
You must be careful not to
close the vault door when
the locking mechanism
cover is removed since
lockout will occur.

1601 W. DEER VALLEY RD. PHOENIX, AZ 85027 | T. 800-552-5669 | F. 623-687-2290 | [e-mail] | KNOXBOX.COM
OPE-ESYSLR-0303-D
©Knox Company. All Rights Reserved
KNOX ELOCK CORE RETROFIT:
KLS-4400 & KLS-4500 INSTALLATION GUIDE
4
Installation of the Knox RainGuard™:
Use the provided alcohol wipe to clean
the backside of the Dust Cover and the
surface area all around the Lock (see note
below regarding Dust Cover Magnet).
Use a sharp instrument to remove the
adhesive backing from the bottom half of
the Knox RainGuard. The bottom half is
the section with the open circle.
10 11
Mount the Knox RainGuard to the Dust
Cover Bracket. The Knox RainGuard’s
open circle will t tightly around the
Lock Shell.
12 Using the nose of the foam as a guide,
fold upper half of the Knox RainGuard
to align with the Lock Core center. The
nose will fold over and into the Lock
Core for protection.
Remove the adhesive backing from the
back side of the Knox RainGuard's upper
half. Pull out and close Dust Cover with
pressure allowing the Knox RainGuard
to rmly attach to the Dust Cover. Lift the
Dust Cover up and press both halves of
the Knox RainGuard for a rm t.
13 14
Lastly, remove the adhesive backing
from the Knox "K" reective label, and
place front and center of the Dust Cover.
15
Remount the protective Lock Mechanism
Cover using the proper sequence of
Aluminum Washers, Fiber Washers and
Mounting Screws.
CRITICAL TEST: Before closing the door
and locking, test the lock mechanism to
make sure the three bolts fully retract and
the mechanism works smoothly. If you hear
a loud click and the lock mechanism stops
working, revisit step 7 before proceeding.
7 8 NOTE:
Do not overtighten Mounting
Screws as this will break the Special
Release Non-Metallic (Fiber)
Washers, and require replacement
with new ones. Use Locktite®on the
screw threads to prevent loosening.
This concludes the Knox eLock Core Retrot Instructions.
9Use your ngers or a at head
screwdriver to remove the Dust Cover
Magnet from the Dust Cover Bracket.