Kaba Mas X-09 1F User manual
INSTALLATION
INSTRUCTIONS
X-09TM
Type 1F
HIGH SECURITY ELECTRONIC LOCK
TABLE OF CONTENTS
INTRODUCTION..............................................................................1
Basic Tools and Materials Needed ................................................... 1
Lock Parts for Installation................................................................. 1
Installation Kit Contents ................................................................... 2
Template ........................................................................................... 3
Preparation for New Installation of the Lock .................................... 4
INSTALLATION ...............................................................................5
Preliminary Lock Installation............................................................. 5
Cutting the Tubes ............................................................................ 6
Installation of the Lock ..................................................................... 7
Installation of the Dial Ring............................................................... 8
Installation of the Cables .................................................................. 8
Installation of Generator Cable and Cable Guides........................... 9
Installation of the Dial Ring Cover .................................................. 10
Cutting and Installing the Spindle .................................................. 10
Installation of the Dial Hub and Dial ............................................... 12
Attach Back Cover Assembly for Testing ....................................... 14
Installation of the Back Cover Assembly........................................ 14
Installation Completion Checklist................................................... 15
Open and Close the X-09 Lock (Factory Combination) ................. 15
APPENDIX A - TUBE RETAINER POSITIONS......................................16
APPENDIX B - CABLE ROUTING DIAGRAMS.....................................17
APPENDIX C - SMALL SPINDLE HOLE INSTALLATION .........................18
11
INTRODUCTION
Please read all instructions before you install and use your Model X-09 lock. This will
help you avoid unnecessary costs and concerns resulting from improper installation.
BASIC TOOLS AND MATERIALS NEEDED
1. Small Phillips head screwdriver (#0)
2. Medium Phillips head screwdriver (#1/#2)
3. Standard hacksaw (32 teeth/inch)
4. Six inch metal scale or ruler
Recommended, but not required:
5. Small flat file
6. Small vise
7. Torque screwdriver (30 inch-pound capacity), or
8. Standard torque wrench with screwdriver bits
Note: See table of recommended torques for the various X-09 lock
screws.
All other necessary tools and materials are provided.
X-09 LOCK PARTS FOR INSTALLATION
1. Lock Assembly
2. Dial Ring
Assembly
3. Dial Assembly
4. Spindle
5. Dial Hub
Assembly
1
2
3
4
5
TABLE OF RECOMMENDED TORQUES FOR THE VARIOUS X-09 LOCK SCREWS
Applications P/N Screw Size Torque (In.Lb.)
Lock Case Cover 105030 6-32 9.0 to 11.0
Dial Ring Mounting 105034 8-32 17.0 to 20.0
Dial Ring Cover 105034 8-32 17.0 to 20.0
Lock Case Mounting 105046/105195 1/4-20 25.0 to 30.0
Figure 1 - X-09 Lock Parts
2
INSTALLATION KIT CONTENTS
1. Rubber Vise Clamp
2. Saw Blade (52 teeth/inch)
3. Saw Handle
4. Tube Deburr Stone
5. Outer Tube
6. Inner Tube
7. Dial Ring Mounting Screws (2)
8. Lock Case Mounting Screws (4)
9. Cover Lock Pin Retainer
10.Cover Lock Spring
11.Cover Lock Pin
12.Stick-on Cable Guides (3)
13.Zebra Connector & Zebra Connector Housing*
14.Lubricant
15.Dial Hub Locating Gauge
16.Hex Key (5/64”)
* The Zebra Connector and Zebra Connector Housing are assembled at the factory
but may come apart during shipment.
Figure 2 - X-09 Installation Kit
3
TEMPLATE
A template is provided as an aid for locating, drilling, and tapping the lock case and
dial ring mounting screw holes relative to the spindle hole. Since the lock is designed
to fit most industry standard container lock mounting screw hole patterns, the need to
use this template should be minimal.
Note: The above template is NOT Actual Size. Do Not Use for locating, drilling,
and tapping the lock. A Template of actual size is included with the lock for
installation purposes.
4
PREPARATION FOR NEW INSTALLATION OF THE LOCK
1. Use the template to establish the exact relative locations of all of the necessary
mounting holes for the lock case and the dial ring, when necessary.
2. The lock case mounting screws require drilled and tapped 1/4-20 screw holes.
3. The dial ring mounting screws require drilled and tapped #8-32 screw holes.
4. The spindle hole must be 3/8 inch diameter, minimum.
Note: If the spindle hole is less than 3/8 inch, refer to Appendix C of the
manual for instruction on small spindle hole installation.
Figure 4- Tube-Cable Assembly Relationships
5
INSTALLATION
PRELIMINARY LOCK INSTALLATION
WARNING: The electronics in the X-09 are susceptible to damage from
Electro Static Discharge (ESD). Make sure you are properly grounded before
removing the lock cover and be careful to avoid touching the connectors on
the card.
1. Remove the two screws from the lock back cover assembly. Hold the case and
pull the cover straight out from the lock case so as not to bend any of the
motor pins on the card assembly.
Caution: The drive cam assembly is
only retained by the lock back cover
assembly. Be careful that it does not fall
out when the cover is removed.
2. Remove the drive cam assembly from
the lock case assembly. (See
Figure 5.)
3. Feed the cables through the outer,
larger, tube starting from the flared
end of the tube. Seat the tube into
position on the tube retainer on the
back of the lock case assembly.
(See Figure 4 ) Be careful to keep the
cables pulled taut while seating the
tube to avoid pinching damage to them.
Alternate Method: Depending on the width of the door, it may be easier
to insert the non-flared end of the outer tube through the spindle hole from
the inside of the container and feed the cables through the tube. Then seat
the flared end of the tube on the tube retainer.
4. Carefully guide the outer tube (keeping it in place on the tube retainer) through
the container wall so that the outer tube and the cables are easily accessible at
the outside wall of the container.
Helpful Hint: If available, another inner tube inserted from the dial ring side,
with the cables carefully fed through it, can be very helpful as a guide in feeding
the cables through the container wall.
On some containers the only way to complete this step is to retract the bolt.
Contact Technical Support for detailed instruction on completing this activity.
Drive Cam
Assembly
Thermal
Relocker
Actuator
Figure 5 - Inside Lock Case Assembly
6
5. Loosely attach the lock case assembly
to the container wall with two of the
four mounting screws, placing them
diagonally across from each other.
6. Tighten the lock case mounting screws
to hold the lock case in place. (See
Figure 6.)
CUTTING THE TUBES
Warning: The end of the large tube that
is to be discarded must be from the plain (unflared) end of the tube. The end of
the small tube that is to be discarded must also be from the plain (unnotched)
end of the tube.
1. Make sure that the outer tube is properly placed over the lock case
tube retainer.
2. While holding the outer tube firmly in its seated position, use a 6 inch scale or
ruler to measure 5/16 inch from the container wall and mark the outer tube at
this length.
3. Remove the lock case assembly from
the container and remove the outer tube
for cutting.
4. Assemble the saw blade and wooden
saw handle provided. To assemble the
saw, grip the saw frame in a vise, just
below the neck. Drive the handle fully
onto the neck. (See Figure 7.) This will
reduce the tendency of the handle to
turn on the saw frame when sawing.
Note: This saw is intended only for
cutting the tubes. A standard hacksaw
should be used to cut the spindle.
5. Insert the tube to be cut into the rubber
vise clamp (provided), with the mark just
beyond the clamp. Then firmly clamp
the rubber vise clamp in a vise. (See
Figure 8.) Use the saw to cut the tube
where marked. Be careful to keep the
cut as straight as possible. Remember
the saw only cuts when pushing. Trying
to cut while pulling may pull the handle
off of the saw blade.
Figure 6 - Tighten Mounting Screws
Figure 7 - Assemble Saw
Figure 8 - Cut Tube Using Vise
7
6. The inside and outside of the tubes
must be deburred after cutting. Use
the stone which is provided for this
purpose. Make sure there are no
sharp edges on either tube inside
and outside so as not to damage the
cables. (See Figure 9.)
7. Install the inner tube on the lock case. Feed
the cables through the outer tube and install
the outer tube on the lock case. Measure and
mark the inner tube to be 1/16 to 1/8 inch
longer than the outer tube. (See Figure 10.)
Remove the inner tube and cut by the same
method as described in Step 5.
Warning: The end of the outer tube that
is to be discarded must be from the plain
(unflared) end of the tube. The end of the
inner tube that is to be discarded must
also be from the plain (unnotched) end of
the tube.
INSTALLATION OF THE LOCK
1. Place the inner tube into the lock case
tube retainer. Make sure that the cutout
in the tube aligns with the cables and
allows the tube to seat completely in the
tube retainer. (See Figure 11.)
2. Feed the cables through the outer tube
from the flared end. Seat the tube into
position on the tube retainer on the back
of the lock case assembly. (See Figure
4 on page 4.) Be careful to keep the
cables pulled taut while seating the tube
to avoid pinching and damaging them.
3. Carefully guide the outer tube (keeping it in place on the tube retainer) through
the container wall so that the outer tube and the cables are easily accessible at
the outside wall of the container, retracting the bolt if necessary.
4. Loosely attach the lock case assembly to the container wall using the lock case
mounting screws.
5. Tighten the lock case mounting screws to the specified torque. (See Figure 6.)
Figure 10 - Inner and
Outer Tubes
Figure 9 - Deburr Tubes
Figure 11 - Seat Inner Tube in Retainer
8
INSTALLATION OF THE DIAL RING
1. Remove the two screws from the dial ring assembly cover and remove
the cover.
Note: Make sure the tubes are projecting through the container as shown
in Figure 10. If not, the tubes are not seated properly in the lock or they were
not cut to the proper length. Correct the problem before proceeding.
2. If necessary, rotate the tube retainer in the dial ring so that the cables come
through the notch in the tube retainer. See Appendix A for details.
3. Feed the cables through the tube retainer on the dial ring assembly and place
the dial ring assembly over the end of the tubes. Make sure the tubes are
seated in the tube retainer on the dial ring assembly.
4. Attach the dial ring to the container with the dial ring mounting screws and
tighten to the specified torque.
INSTALLATION OF THE CABLES
1. Open the ZIF (Zero Insertion Force) seal cover and move the ZIF connector
locking actuators outward to their open position. (See Figures 12 and 13.)
2. Plug the cables into the ZIF connectors with the bright metal tabs on the cables
facing toward the circuit board to which the ZIF connectors are mounted. Push
the cables into the connectors as far as they will go.
3. Close the ZIF locking actuators to lock the cables in place.
4. Close the ZIF seal cover. When closing, be sure the tenons in the seal cover
align with the holes in the coordinating piece of the seal cover.
Figure 12 - Open ZIF Seal Cover Figure 13 - Closed & Open ZIF
Connectors
Seal Cover
ZIF Connectors
Closed Open
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