Kaba Mas X-09 1F Manuel utilisateur

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

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

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

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

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.

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

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

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

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

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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