Kaba Mas DKX Series User manual

Kaba Mas LLC
DKX Series
Type III
Installation Instructions
June 16, 2020
550.1026
REV. -B
June 2020

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TABLE OF CONTENTS
INTRODUCTION ................................................................................................... 4
DKX-10 Type III Components ........................................................................ 5
dormakaba PowerPlex P2000 Self Powered Access Control Lock........... 5
Dorma F9300 3-hour Fire Rated Exit Device ........................................... 5
CDX-10 High Security Pedestrian Door Lock............................................ 5
DKX-10 Type III Installation........................................................................... 5
DETERMINE DOOR HANDING ............................................................................. 6
Left-hand....................................................................................................... 6
Right-hand .................................................................................................... 6
Left-hand Reverse......................................................................................... 6
Right-hand Reverse....................................................................................... 6
INSTALLATION PREPARATION............................................................................. 7
Required Tools.............................................................................................. 7
PARTS CHECKLIST ................................................................................................ 8
dormakaba PowerPlex P2000....................................................................... 8
Dorma F9300 Fire Rated Exit Device............................................................. 9
Covers and Other Parts............................................................................... 10
Reference.................................................................................................... 10
CDX-10 High Security Lock .......................................................................... 11
Kit Contents ................................................................................................ 12
INSTALLATION (Phase One) .............................................................................. 13
dormakaba PowerPlex P2000..................................................................... 13
Install Optional K-I-L or BEST Removable Core Override and Outside
Lever ........................................................................................................... 15
For BEST Removable Core........................................................................... 16
For Optional K-I-L Key ............................................................................... 17
Test the Operation of the Outside Lever .................................................... 18
Test the Movement of the Lever (without the key in cylinder).................. 19
Test the Mechanical Key Override with Change Key .................................. 19
Change Key-in-Lever Lock Cylinders ........................................................... 20
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Change BEST-Type Core.............................................................................. 21
Remove and Reassemble the Outside Lever .............................................. 21
Testing the Operation of the Lock .............................................................. 22
INSTALLATION (Phase Two) .............................................................................. 23
Dorma F9300 Fire Rated ............................................................................. 23
Install Strike ................................................................................................ 24
Install Panic Bar and Rail Assembly to Door ............................................... 25
Install End Cap ............................................................................................ 25
General Maintenance Notes....................................................................... 25
INSTALLATION (Phase Three)............................................................................ 26
Install DKX-10/DKX-19 Lock Strike................................................................ 26
DKX-10/DKX-19 High Security Lock Installation............................................ 27
Cut the Tubes................................................................................................ 28
DKX-10/DKX-19 High Security Lock Installation (Continued) ....................... 28
Install the Dial Ring....................................................................................... 29
Install the Cables .......................................................................................... 29
Install Generator Cable and Cable Guides.................................................... 30
Install the Dial Ring Cover............................................................................. 30
Cut and Install the Spindle............................................................................ 30
Install the Dial Hub and Dial ......................................................................... 31
Interface Hardware ...................................................................................... 32
Cable Assembly.................................................................................... 32
Install Knob Lever Assembly ................................................................ 32
Install Lock Cable Assembly ................................................................. 33
Install Cable Assembly ......................................................................... 34
Connect Cable Assemblies................................................................... 34
Adjust Cable Length............................................................................. 34
Covers........................................................................................................... 35
Install Chassis Cover ............................................................................ 35
Install Lock Cover................................................................................. 36
Install Manual O/R Knob Label ........................................................... 36
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INTRODUCTION
The Kaba Mas DKX-10 Type III is General Services Administration (GSA)
approved. It complies with Federal Specification FF-L-2890C. The DKX-10 Type
III comes with a modified Kaba Mas CDX-10. The DKX-19, Type III option comes
with a modified S&G 2740 combination lock in place
of the X-10.
Please read all directions carefully.
These instructions are designed for use by technicians and locksmiths familiar
with common safety practices and competent to perform the
steps described.
Caution: Kaba Mas is not responsible for damage or malfunction due to
incorrect installation.
Notes:
1. Carefully inspect doorframe, door, and hinges to ensure the door and
frame fit and operate correctly.
2. The installer should ensure that the door meets all building, fire, and
security code requirements prior to installing the
DKX-10 Type III.
3. Kaba Mas recommends the installer of the DKX-10 is properly trained
on the Kaba Mas DKX-10 Type III, Pedestrian Door Lock. (Contact Kaba
Mas at 859-479-1329 for DKX-10 Certification Training and training
dates.)
4. The Kaba Mas X-10 is protected from Electrostatic Discharge (ESD).
However, it can be damaged during the installation process if proper
precautions are not taken. Follow these precautions to avoid ESD
damage when installing a modified CDX-10 High Security Lock.
A. For best protection, use an ESD wristband
grounded to the lock during installation.
B. Do not touch the end of the flex cable if the
ESD protective cover has been removed.
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DKX-10 TYPE III COMPONENTS
Installation of the DKX-10 Type III consists of three main components, linkage,
and associated hardware:
1. The dormakaba PowerPlex P2000 Self Powered Access Control Lock
2. The Dorma F9F 3-hour Fire Rated Exit Device
3. A modified Kaba Mas CDX-10 High Security Pedestrian Door Lock
Installation of the DKX-10 Type III consists of four (4) steps:
1. Installation of the dormakaba PowerPlex P2000 Exit Device Trim
2. Installation of a Dorma F9300 Fire Rated Exit Device
3. Installation of a modified CDX-10 High Security Lock
4. Installation and adjustment of linkage
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DETERMINE DOOR HANDING
Determine whether the door is left-hand (LH), right-hand (RH), left-hand
reverse (LHR) or right-hand reverse (RHR) by referring to Figure 1.
OUTSIDE
Left- hand
Right- hand
Left-hand
Reverse
Right-hand
Reverse
Figure 1
OUTSIDE
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INSTALLATION PREPARATION
Required Tools For Installation:
•Level
•#2 Phillips Head “Stubby” Screwdriver
•#3 Phillips Screwdriver
•Center Punch
•1" Hole Saw
•3/8" Box End Wrench
•Hacksaw
•File
•6" Scale
•Tape Measure
•Electric Drill Motor
•Drill Bit Set
•Rubber Mallet
•Vise
•Hex Key Set
•Small Pick
•Ruler
•Torque Wrench
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PARTS CHECKLIST
dormakaba PowerPlex P2000
A. Outside Lever Handle
B. Outside Housing
C. Gasket (when required)
D. Spindle(s)
E. Inside Adaptor Plate
F. Mounting Screws 12-24 1/8" Hex (3)
G. Flat Washer ½ OD (2 or 4)
H. Pan Head Screws 10-24 ¾" (4)
I. Chassis
J. Inside Chassis Cover
K. Cylinder Plug
L. Cylinder
M. Cylinder Cap
N. Outside Lever Handle
E
Figure 2
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Dorma F9300 Fire Rated Exit Device
Parts
•R.H.P.M.S: Round Head Phillips Machine Screw
•R.H.P.T.S: Round Head Partial Thread Screw
•R.H.P.M.S: Round Head Phillips Machine Screw
•F.H.P.M.S: Flat Head Phillips Machine Screw
•F.H.P.T.S: Flat Head Partial Thread Screw
Figure 3
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Covers and Other Parts:
•Universal Chassis Cover (515030)
•RHR Lock Cover (515031)
•LHR Lock Cover (515032)
•End Cap (515038)
•Retainer Clip (515041)
•Cable Connector Rod End (515040)(LHR - Short)
•Cable Connector Rod End (515029)(RHR - Long)
•Cable Assembly (115036)
•Hex Nut, Brass (115123)
•Lock Cover Bracket (515034)
Reference:
•Lever Knob Cam (515027) (LHR-Short)
•Lubricant (9810004)(not shown)
•Rod Connector and Cable Assembly (514033) (RHR-Long)
•Retainer Clip (515041)
•Cable Connector Rod End (515040)(LHR-Short)
•Cable Connector Rod End (515029)(RHR- Long)
•Brass Hex Nut, Brass (115123)
•Cable Assembly (116036)
•Cable Connector Rod End (515027)(RHR-Short)
Figure 4
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CDX-10 High Security Lock:
1. Mounting Plates
2. DKX-10 Lock Body and Baseplate
3. Spindle
4. Dial Assembly
5. Installation Instructions
6. Installation Kit
7. Backing Plate
8. Hub
9. Screw Kit
10. #2 Strike
11. Escutcheon Plate
Figure 5
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Kit Contents
1. Saw Handle
2. Saw Blade (52 teeth/inch)
3. Vise Clamp
4. Tube Deburr Stone
5. Outer Tube
6. Inner Tube
7. Stick-on Cable Guides (3)
8. Zebra Connector and Housing
9. Lubricant
10. Dial-Hub Locating Gauge
11. Spindle 6-32 Screw
12. Dial Ring to Exterior Mounting Plate Mounting Screws, Pan Head #8-32
x 5/16” (2)
13. Hex Key
14. CDX-10 Stabilizing Screws, Pan Head #10 x 1.25”, Type AB (2)
15. CDX-10 Exterior Mounting Plate Attaching Screws, Pan Head #10-32 x
1.25” (4) (For thicker doors, you may need to use longer 10-32 pan
head screws.)
Figure 6
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INSTALLATION (Phase One)
dormakaba PowerPlex P2000
A. Use the template and mark the desired handle height on the edge of the door.
(See Figure 7.) Note: Recommended centerline is 40 5/16".
B. Use the template and mark a 2 3/8" backset vertical line (or the appropriate
backset for your installation). Mark a horizontal line 40 5/16" above the floor.
C. Position the template on the inside of the door aligning the door handle
height mark and backset vertical line mark with the lines on the template. Use
masking tape to secure the template to the door. Mark the position of the
holes on the door. Remove template.
D. Using a 3/16" drill bit, drill the pilot holes to the appropriate depth as indicated
on the template.
E. Enlarge the pilot holes to the size that is indicated on the template. Note: It is
recommended that you drill from both sides of the door to eliminate the
possibility of splintering.
Note: Drill the holes in the door required for the exit device as indicated on the template.
(4)Holes
1/2”
Backset Vertical Line
From the inside, counter bore
(4) 3/8" dia. × 1/2"deep holes.
See Drilling Template
Figure 8
Figure 7
1"
Through
Hole
(3) 3/8" Through Holes
From the inside, counter bore
(4) 3/8" dia. × 1/2"deep holes.
See Drilling Template
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F. Install the Outside Lever of dormakaba PowerPlex P2000.
A. Assemble the lever on the outside housing, in the horizontal rest position
appropriate to the handing of the door as shown. Simply push the lever onto
the tube until it clicks in place. If more force is required to engage the handle,
use a rubber mallet. Test the setting of the handle by pulling on it.
B. Use the 5/32" hex key, tighten the set screw while pushing the lever against the
plastic washer to remove the lever play .
C. The lever is reversible. If the handing is incorrect, insert a small pick or flat
screwdriver in the hole in the hub as shown. Gently pry back the spring clip
inside the hub and remove the handle.
Figure 9
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Install Optional K-I-L or BEST Removable Core Override
and Outside Lever
Upon unpacking, the lock housing with
mechanical override should look like
the diagram below with:
•The small indents (i) on the
cross of the override shaft (m)
in-line horizontally
•The plastic washer (c)
on the drive tube
•The lever catch (f) in the
out position
•Cylinder (j) and 2 keys (n)
(included in the hardware bag)
•Shaft override tool (o)
(included in the hardware bag)
A. Push in the lever catch (f) firmly.
B. Insert the cylinder (j) into
the lever handle (h).
Figure 10
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Note: When using BEST Interchangeable cores, use
steps below .
For BEST Removable Core
A. Insert 6-pin BEST adapter (thicker)
into 6-pin interchangeable core or
insert 7-pin BEST adapter (thinner)
into 7- pin interchangeable core.
Insert the adapter until it makes
contact with the removable core.
B. Use the control key and assemble
the removable core with its adapter
into the lever. Remove control key.
C. Insert the change key into the
removable core.
Figure 11
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For Optional K-I-L Key
A. Put the cylinder plug (k) into the lever (h).
B. Ensure that the cylinder plug (k) does not fall
out, insert the key into the cylinder (j). (The
key will be horizontal.)
C. For Right-handed Levers: Turn the key
clockwise until it stops so that it is in the
vertical position and the countersink (g) is in
the top position.
For Left-handed Levers: Turn the key
clockwise until it stops so that it is in the
vertical position and the countersink (g) is in
the bottom position .
D. Fit the lever handle (h) onto the drive tube. It
should rest approximately 1⁄16" (2mm) from
the body of the housing. If it can’t be pushed
that close to the housing, the lever catch (f) is
probably not pushed in. Push it in. If the lever
catch (f) is stuck, the override shaft is in the
wrong position. The two small indents on the
cross of the override shaft must be vertically
aligned.
E. Press the lever firmly against the housing
while turning the key counterclockwise
(This applies to both right-handed and left-
handed locks.) until it is in the horizontal
position.
Caution: The position of the key is very important. If the lever is not assembled
with the key in the correct position before placing the lever on the housing, the
inside mechanism of the lock could be damaged if the lever is rotated and forced.
Important: If it is not possible to turn the key
counterclockwise to complete this step, the spring
washer (d) may be too tense. Tap the lever carefully
with a rubber mallet to loosen the spring washer
(d). Cover the lever handle with a cloth or other
material to protect the finish of the metal.
j
Figure 12
Figure 13
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F. Remove the key. (The lock will look as shown at right.)
G. Gently check the rotation of the lever handle.
(It should easily rotate approximately 45º.)
H. Use the 5/32" hex key and tighten the set screw
while pushing the lever against the plastic
washer to remove the lever play .
Test the Operation of the Outside Lever
Verify that the lever has been correctly attached to the housing :
A. Remove key.
B. Insert a small flat screwdriver into the hole on the underside of the lever
handle and push in the lever catch.
C. Pull on the lever.
(You should not be able to remove the lever. If the lever comes off of the housing, the
lock is not assembled correctly. Re-do steps A-C in Phase One/Section E- Install the
Outside Lever of dormakaba PowerPlex P2000.)
Troubleshooting: If you have assembled the lever and housing
with the key in the wrong position, the key will get stuck. To
remove the key, turn it so that it is in the vertical position and
insert a small flat screwdriver into the hole under the lever handle
to push the lever catch in (f). Remove key. If it is still stuck, turn the
key clockwise until it stops to the horizontal position and push the
lever catch in again with the small screwdriver. Remove key.
Right-Handed lock
Left-handed lock
Troubleshooting:
Right-handed Lock: Turn the lever handle clockwise without forcing it. If it stops at
approximately 15º, it was not assembled correctly. Do not try to force it to turn—this
will damage the inside mechanism of the lock. Release the lever handle. Insert the
small screwdriver into the small hole on the underside of the lever handle and push in
the lever catch.
Re-do steps A-C in Phase One/Section E- Install the Outside Lever of dormakaba
PowerPlex P2000.
Left-handed Lock: Turn the lever handle counterclockwise without forcing. The drive
hub should not rotate when the lever handle is turned. If it does, it was not assembled
correctly. Release the lever handle. Insert the small screwdriver into the small hole on
the underside of the lever handle and push in the lever catch.
Re-do steps A-C in Phase One/Section E- Install the Outside Lever of dormakaba
PowerPlex P2000.
Figure 14
Figure 15
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A. Turn the lever (h) clockwise for a right-handed lock or
counterclockwise for a left-handed lock.
B. Release the lever slowly. It should return freely to its
horizontal position.
Test the Mechanical Key Override with Change Key
A. Without using the key, turn the lever clockwise for right-
handed locks or counterclockwise for left-handed locks. The
inside drive hub should not rotate when the lever turns.
B. With the lever (h) in the horizontal position, insert the key
(n) into the cylinder and turn it clockwise until it stops. (This
applies to both right and left-handed locks.)
C. Let go of the key, and again turn the lever handle
(h) clockwise for right-handed locks or counterclockwise for
left-handed locks. Now the inside drive hub (b) should
rotate in the same direction as the lever handle when it is
turned.
Test the Movement of the Lever (without the key in
cylinder):
Important: The key override itself does not retract the latch or deadbolt. Do not
use too much force when turning the key as this may damage the unit. To retract
the latch, turn the key clockwise until it stops, release the key and turn the lever.
Note: The lever must stay in the horizontal position when turning
the key (Do not try to turn the key while turning the lever.) or the
override mechanism will not work.
Figure 16
Figure 17
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D. Install cap (i) to cover keyhole. The cap has a
small groove on one edge to allow ease of
removal. This should be facing down. Insert
bottom snap of cap in lever hole below the
cylinder. With a small screwdriver, push top snap
of cap down while pushing the cap into place.
E. To remove the cap (i), insert a small flat
screwdriver into this groove and gently pry the
cap off, being careful not to damage it. Cover the
bottom of the lever to protect the finish from
being scratched through the process of removing
the cap.
Change Key-in-Lever Lock Cylinders
A. Loosen the set screw to free the lever. (just 1/4to
1/2turn)
B. Remove the cap from the outside lever (h).
C. Insert key (n).
D. Turn the key clockwise until it stops.
E. Release key (n).
F. Use a small flat screwdriver to push in the lever
catch through the small hole underneath the
outside lever.
G. Pull the outside lever (h) off of the lock housing.
(Be careful not to lose the cylinder plug (k).
If it is difficult to pull the lever, slightly tighten or
loosen the set screw.)
H. Replace the old cylinder with the new one in the
lever handle. (Only the same kind of cylinder
with 2 grooves in cross in the end of the cylinder
plug can be used on the lock.)
I. Re-insert the cylinder plug (k).
J. Hold the cylinder (j) and plug (k) in place, insert
the key.
Follow steps For K-I-L Key C to H and test as per Test the
Operation of the Outside Lever, and Test the Mechanical
Key Override with Change Key instructions.
Figure 18
Figure 19
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