DOM ix Gamma User manual

ix Gamma
298349 / 0 / gb / 10.11 / Revision C
Assembly instructions
Reversible key system
ix Gamma

Notes
ix Gamma

ix Gamma Contents
ix Gamma
1
Contents
PRODUCT DESCRIPTION ........................................................................................ 3
FOR YOUR SECURITY ............................................................................................. 4
Important notes........................................................................................................ 4
SCOPE OF DELIVERY.............................................................................................. 5
PREPARATION ......................................................................................................... 6
Tools........................................................................................................................ 6
Service box.............................................................................................................. 7
ASSEMBLY................................................................................................................ 8
Preparing the assembly structures........................................................................... 9
Filling the cylinder body.......................................................................................... 13
Filling the cylinder core .......................................................................................... 20
Inserting the cylinder core in the cylinder body...................................................... 23
Type 333................................................................................................................ 24
Type 333H ............................................................................................................. 26
Type 333T.............................................................................................................. 28
Type 333K.............................................................................................................. 30
Type 333KL............................................................................................................ 33
Type 382................................................................................................................ 35
Type 555................................................................................................................ 37
Type 777................................................................................................................ 39
MAINTENANCE....................................................................................................... 41
STORAGE/MAINTENANCE .................................................................................... 41
DISPOSAL............................................................................................................... 41
TECHNICAL DATA OF IX GAMMA......................................................................... 42

Contents
ix Gamma
2
WARRANTY............................................................................................................. 44
LOCKING PLAN ...................................................................................................... 45
SPARE PARTS (FAX TEMPLATE) ......................................................................... 47

ix Gamma Product description
ix Gamma
3
Product description
The focus of the DOM ix Gamma system is a small ball which is supported in a freely
movable fashion. Due to this technology, it is practically impossible to copy the key.
The DOM ix Gamma system does not only prevent unauthorised copies but also me-
chanical acts of violence. The ball is made of high-alloyed stainless steel with stan-
dard drill protection devices.
An identification card for individual locking systems or a service card for general lock-
ing systems is provided together with the ix Gamma system. This is for your addi-
tional special security! The DOM Service Centre only accepts orders for duplicate
keys upon the presentation of this card.
You can insert the ix Gamma reversible key in any position: it always fits. This is not
only very practical and user-friendly but also very convenient! No big bunch of keys
for house owners. Whether entrance door, apartment door, cellar door, lock for the
mailbox or the garage - one key fits for all with the innovative ix Gamma locking sys-
tem.
The cylinder is available in massive or in modular design, and it can be used for all
kinds of locking systems.

For your security/Important notes
ix Gamma
4
For your security
Make sure that you always follow the notes and safety information!
Some chapters in this document are marked with icons. Please memorise the icons
and their meaning:
Caution! This icon stands for a hazard note and/or indicates an action
which might cause damage to the mechanical cylinder or other items.
Note! This sign points out to useful information with regard to assembly.
Important notes
Caution! Keep the locking cylinder and its components away from small
children. They might swallow these components.
Caution! Material damages resulting from incorrect storage. If you store
the locking cylinder for a longer period of time before you use it, you must
store all components in original packaging at a dry and dust-free place.
Caution! Damages resulting from incorrect assembly. Please read the
complete instructions carefully before assembly. Follow the instructions
step by step: The manufacturer does not assume any liability for dam-
ages resulting from incorrect assembly.
Caution! Damages caused by untrained staff. DOM cylinders may only
be assembled by thoroughly trained staff. The manufacturer does not
assume any liability for damages caused by untrained staff.
Note! In order to ensure the quick processing of your order we would
kindly ask you to use the order forms in the "Spare parts" chapter. All
standard cylinders are listed on this form. Please copy the order forms
before completing them so that you have a blank order form available at
any time.
Note! Our master key set includes nine keys (0-7 borehole depth) and
one profiling key (without boreholes).

ix Gamma Scope of delivery
ix Gamma
5
Scope of delivery
Each ix Gamma delivery includes the following documents:
1. Service card
2. Customer locking plan
3. Coded locking plan
4. Table with the assembly structures of the cylinders
5. Supplementary sheet for subordinate keys
You can use the locking plan, the table with the assembly structures of the cylinders
and the supplementary sheet for subordinate keys for the fabrication of replacement
cylinders and replacement keys. The customer ordering the locking system will be
provided with the service card and the customer locking plan.
Note! The customer ordering the locking system must keep the service
card at a safe place which can only be accessed by authorised persons.

Preparation/Tools
ix Gamma
6
Preparation
In order to ensure correct assembly, you need the assembly structures, the correct
core pins and body pins as well appropriate tools.
Caution! Damages resulting from incorrect assembly. Please read the
complete instructions carefully before assembly. Follow the instructions
step by step: The manufacturer does not assume any liability for dam-
ages resulting from incorrect assembly.
Caution! Damages caused by untrained staff. DOM cylinders may only
be assembled by thoroughly trained staff. The manufacturer does not
assume any liability for damages caused by untrained staff.
Tools
Caution! Damages resulting from incorrectly applied tools. The tools of-
fered by DOM Sicherheitstechnik for cylinder assembly meet the re-
quirements of correct assembly. The manufacturer does not assume any
liability for damages or incorrect assembly resulting from the use of dif-
ferent tools.
You need the following tools:
1
23
45
6
7
Ill. 1: Tool
1: Assembly clam (406222)
2: Loading knife (263623)
3: Follower (403445)
4: Assembly clam for TYPE 382
(406233)
5: Pliers for the TYPE KL cam
(265776)
6: Pliers for extensions (261669)
7: Pliers for the cam (263629)

ix Gamma Preparation/Service box
ix Gamma
7
Service box
DOM Sicherheitstechnik prepared an Service box for the ix Gamma system including
all pins (body pins, core pins) as well as master key wafers. With this Service box
which you can directly order at DOM Sicherheitstechnik you are equipped with any
necessary gears and pins at any time.
Note! This Service box is also available for further systems such as ix 6
KG, Diamant, etc.
Core pins
N N N AF AF AF AF AF
No. 0 No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7
4.85 mm 5.25 mm 5.65 mm 6.05 mm 6.45 mm 6.85 mm 7.25 mm 7.65 mm
505280 505281 505282 505095 505096 505097 505098 505099
AF Profile pin Profile pin
No. 8 No. 1, 2, 3 No. 4, 5, 6
8.05 mm A, B, C 7, 8, 9, 0
505100 242637 207464
4,9 mm 4.5 mm
Cam Core end piece Standard Double-entry Standard Double-entry
HLB HLB cam cam coupling coupling
218426 008 204217 218228 008 248386 008 217397 501006
Body pins
N N N AB FB
No. 0, 1, 2 No. 3, 4, 5, 6 No. 7, 8 No. 0, 1, 2 No. 3, 4, 5, 6
5.5 mm 4.5 mm 3.5 mm 5.5 mm 4.5 mm
201680 201681 201682 201675 112 505492
Master key wafers Master key wafers Master key wafers Master key wafers Ball KG
core pin
0.8 mm 1.6 mm 2.4 mm 3.2 mm ø 2.1 mm
212563 245869 500134 500135 235898 511589
H H H H H KG
No. 0 No. 1, 2 No. 3, 4 No. 5, 6 No. 7, 8 core pin
5.6 mm 4.6 mm 4.1 mm 3.1 mm 2.3 mm
201594 002 201596 002 201597 002 201599 002 222260 002 220836
382, 393 382, 393 382, 393 382, 393 382, 393
Pressure spring Pressure spring KG functional Security ring
RD 3x15 V2A spring
RD 1.4x6 1.0 mm
202056 239465 217706 202335F
333, 555, 777 382, 393
The Service box has individual compartments where you can arrange the pins. On
the illustration you can see the arrangement of the pins as packed ex works.
Note! The Service box includes a list of contents. In order to avoid confu-
sion, it is important to adopt the order of the pins according to the list of
contents.
Note! It is possible on request to supply the assembly tools together with
the Service box.

Assembly
ix Gamma
8
Assembly
Please follow the steps as indicated in the instructions and observe the notes and
illustrations.
Caution! Only use the special tools described in each assembly step. The
manufacturer does not assume any liability for damages resulting from
the use of inappropriate tools.
Note! Use a soft surface for assembly (e.g. foamed material). Using such
a surface ensures that no pins will escape from the cylinder core when
inserting the core into the body.
Note! The material numbers for all standard components will be listed
with each assembly step.
The assembly instructions first describe the general assembly steps which apply for
all cylinder types, for example how to handle the assembly structures, body filling,
core filling and how to mount the core into the body. Then the assembly steps for
each specific cylinder type are described.

ix Gamma Assembly/Preparing the assembly structures
ix Gamma
9
Preparing the assembly structures
With each ix Gamma delivery you will be provided with a sheet including a table with
the assembly structures of the cylinders. If the positions of the FB/AB body pins are
not provided in the table ex works, you must fill in the pins in the table.
The following generally applies:
One N body pin is always mounted to position 5.
The FB/AB body pins may only be mounted at the first four positions, maximal 2
pins for each cylinder side.
FB/AB body pins are mounted to the positions with the lowest values. For super-
structures (locking systems), the lowest value including the superstructure is taken
into account.
For 0, 1, 2 lengths, only N pins and for 3, 4, 5, 6, 7, 8 lengths, only AF pins are avail-
able as core pins. Core pins are not restricted with regard to positions. The core
pins are applied at the positions P1 - P 5 depending on their lengths.
Assembly structure without master key wafers
Body pins
4
5
1
2
3
AB
FB
P1
P2
P3
P4
P5
4
5
1
2
3
N
N
AB
FB
N
P1
P2
P3
P4
P5
1.) First, 2 FB/AB body pins are applied at the posi-
tions P1 - P4 with the smallest values.
(in this case: position P3 = value 1 and P4 = value
2)
2.) The N pins are applied at the remaining posi-
tions.

Assembly/Preparing the assembly structures
ix Gamma
10
Assembly structure with master key wafers
Body pins
4
5
1
2
3
3
4
5
6
7
P1
P2
P3
P4
P5
4
5
1
2
3
3
4
5
6
7
FB
N
AB
N
N
P1
P2
P3
P4
P5
4
5
1
2
3
3
4
5
6
7
FB
N
AB
N
N
P1
P2
P3
P4
P5
For assembly structures with master key wafers, the
highest wafer structure determines the body pin as
illustrated in the bottom lines of each column.
1.) First, 2 FB/AB body pins are applied at the posi-
tions P1 - P4 with the smallest values at the bottom
lines.
(here: position P1 = value 4 and P3 = value)
2.) The N pins are applied at the remaining positions
P2, P4 and P5.

ix Gamma Assembly/Preparing the assembly structures
ix Gamma
11
Assembly structure without master key wafers
Note! For 0, 1, 2 lengths, only N pins and for 3, 4, 5, 6, 7, 8 lengths, only
AF pins are available as core pins.
Core pins
AF
AF
N
N
AF
4
5
1
2
3
P1
P2
P3
P4
P5
The core pins are applied at the positions P1 - P 5,
depending on their lengths.
(here: position P1, P2 and P5: AF pin;
position P3 and P4: N pin)
Assembly structure with master key wafers
Core pins
AF
AF
N
N
AF
4
5
1
2
3
3
4
5
6
7
P1
P2
P3
P4
P5
For assembly structures with master key wafers, the
values of the core pins are listed in the top lines.
The pins are assigned in the same way as this is the
case for assembly structures without master key wa-
fers. (see above)

Assembly/Preparing the assembly structures
ix Gamma
12
Example for locking without master key wafers
Core pins
N
AF
N
N
AF
0
4
1
2
6
AB
N
AB
N
N
Gehäusestifte
Core pins are not restricted with regard to positions.
Therefore, an AF core pin is applied at position P5,
depending on length.
Example for locking with master key wafers
Core pins
AF
AF
AF
AF
AF
3
4
7
5
3
5
N
FB
N
FB
N
Body pins
If two values of the body pins are equal (here: length 5
on position 1 and 4), the FB/AB body pin must be ap-
plied to the position without master key wafer.

ix Gamma Assembly/Filling the cylinder body
ix Gamma
13
Filling the cylinder body
Note! Depending on the length of the locking sides, two different core
lengths are applied: core 0 (511592) and core 5 (511593). Compared to
core 0, core 5 is extended by 5mm. For cylinders which deviate from the
standard size, you must apply a core extension with cylinder pin, if nec-
essary.
Double cylinder
A B A B A B A B
30 30 0 0 --- --- --- ---
35 30 5 0 --- --- 246289 ---
40 30 0 0 203643 --- 249759 ---
45 30 0 0 203644 --- 246291 ---
50 30 0 0 203645 --- 246292 ---
55 30 0 0 203643+44 --- 246293 ---
60 30 0 0 203643+45 --- 246294 ---
65 30 0 0 203644+45 --- 246295 ---
70 30 0 0 203647 --- 246296 ---
35 35 5 5 --- --- 246289 246289
40 35 0 5 203643 --- 249759 246289
45 35 0 5 203644 --- 246291 246289
50 35 0 5 203645 --- 246292 246289
55 35 0 5 203643+44 --- 246293 246289
60 35 0 5 203643+45 --- 246294 246289
65 35 0 5 203644+45 --- 246295 246289
40 40 0 0 203643 203643 249759 249759
45 40 0 0 203644 203643 246291 249759
50 40 0 0 203645 203643 246292 249759
55 40 0 0 203643+44 203643 246293 249759
60 40 0 0 203643+45 203643 246294 249759
45 45 5 5 203643 203643 246291 246291
50 45 5 5 203644 203643 246292 246291
55 45 5 5 203645 203643 246293 246291
50 50 5 5 203644 203644 246292 246292
Halve cylinder
203645
---
---
203643
203644
50
0
5
0
5
5
30
35
40
45
Length (mm)
Core
Core extention
Lock side (mm)
Core
Core extention
Cylinder pin

Assembly/Filling the cylinder body
ix Gamma
14
Ill. 2: Applying an extension piece
1. If necessary, you must apply a
core extension with an appropriate
cylinder pin.
Note! Keep ready the table with assembly structures. The body pins are
always listed in the bottom line of each column. The pins in the following
table with assembly structures are highlighted in grey.
Body pins
0
3
1
4
1
Profile:
2
5
1238B
4
5
6
Example
N
N
AB
FB
N
P1
P2
P3
P4
P5
Type 382
H
H
H
H
H
Body pins
N: 0 –2: 201680 = 5.5 mm
3 –6: 201681 = 4.5 mm
7 –8: 201682 = 3.5 mm
AB: 0 –2: 201675 112 = 5.5 mm
FB: 3 –6: 505492 = 4.5 mm
H: 0: 201594 002 = 5.6 mm
1: 201596 002 = 4.6 mm
2: 201596 002 = 4.6 mm
3: 201597 002 = 4.1 mm
4: 201597 002 = 4.1 mm
5: 201599 002 = 3.1 mm
6: 201599 002 = 3.1 mm
7: 201599 002 = 3.1 mm
8: 222260 002 = 2.3 mm
Note! If hollow body pins (type 382) are used, there is no need of N and
FB/AB body pins.

ix Gamma Assembly/Filling the cylinder body
ix Gamma
15
Caution! The position and the number of pin types is specified:
FB/AB pins: 2 FB/AB body pins must be applied at each locking side.
Apply FB/AB body pins only at position P1 - P4, namely at the position
with the smallest values (here: P3 and P4).
N pin: Apply at least 3 N body pins at each locking side.
Note! Insert the pins on the list from the left to the right into the follower
from the inside to the outside.
innen 6 5145
AB
FBN
N
N
KG
außen
Ill. 3: Cylinder assembly structure
body pins
2. Select the required body pins.
(In the follower from the inside to the
outside)
Ill. 4: Filling the follower
3. Insert the body pins into the fol-
lower according to the specified
position.
4. Apply the pressure springs
(202056) to the pins.
5. Insert the KG body pin (220836)
into the provided borehole of the
follower.
6. Apply the KG function spring
(217706) to the KG body pin.
7. Use the loading knife to press the
springs into the follower until the
knife is flush with the follower.

Assembly/Filling the cylinder body
ix Gamma
16
Caution! If you insert the follower incorrectly, you might damage the ma-
terial. If you insert the follower too deep or not deep enough into the cyl-
inder body, you might destroy the pressure springs.
Caution!
Ill. 5: Inserting the follower into the cylinder
body using an loading knife.
8. Carefully insert follower plus load-
ing knife into the cylinder body until
the front edge of the follower is
flush with the internal edge of the
body (basic length: 30mm)) and/or
the security ring support (extended
version).
The springs and pins now are above
the boreholes in the cylinder body.
180°
Ill. 6: Rotating follower with loading knife
9. Rotate follower plus loading knife
until the loading knife is above the
boreholes in the cylinder body.

ix Gamma Assembly/Filling the cylinder body
ix Gamma
17
Ill. 7: Removing loading knife
10.Now you must remove the loading
knife.
11.Carefully rotate the follower to and
fro until the body pins and springs
insert/engage in the provided
boreholes.
Ill. 8: Reinserting loading knife above the
pins
12.Now carefully reinsert the loading
knife above the pins.

Assembly/Filling the cylinder body
ix Gamma
18
Ill. 9: Fixing springs and pins in the cylinder
body
13.Carefully press the pins against the
spring force into the cylinder body
until the rod can be rotated.
14.Rotate follower until the large
groove is above the boreholes in
the cylinder body.
Ill. 10: Removing the loading knife
15.Remove the loading knife.
Note! If you assemble type 555 (without Assembly clam), you must leave
the follower in the cylinder body and proceed on page 20 and first fill the
cylinder core.
If you assemble type 382, you must insert the Assembly clam from the
rear side.