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

9
INSTALLATION OF GENERATOR CABLE
AND CABLE GUIDES
1. Place the generator cable into the dial ring housing recess containing a post
used for positioning the cable. (See diagrams in Appendix B.) The hole in the
cable must be positioned over the post on the dial ring, and the five gold tabs
must be exposed.
2. The Zebra connector and Zebra connector housing are assembled at the
factory but may come apart during shipment. If so, insert the Zebra connector
back into the Zebra connector housing before proceeding.
CAUTION: The Zebra connector is an
electrical connector. Keep it clean!
3. Place the generator Zebra connector
and connector housing assembly over
the generator cable, and press it into the
recess. The hole in the Zebra connector
housing must be positioned over the post
in the dial ring. Be sure that the black Zebra
connector housing is positioned as shown
in Figure 15.
4. Install at least one of the stick-on cable
guides in an appropriate position to restrain the cables. (See Figure 16 for
possible locations.)
5. Route the cables through the cable guide that was just installed.
Figure 14 - LCD and ZIF connectors
Figure 15 - Zebra Assembly
ZEBRA CONNECTOR HOUSING

10
6. Depending on the thickness of the container, additional cable guides may
be necessary to ensure the cables are sufficiently restrained. Some possible
locations are shown in Figure 16. Install additional guides as needed, and route
the LCD and generator cables through them to ensure that the cables do not
get routed through the “KEEP CLEAR” area, over the Zebra connector, or near
where the geared end of the dial hub will project through the dial ring cover.
Note: See Appendix B for more detail on routing the cables.
INSTALLATION OF THE
DIAL RING COVER
1. Align the dial ring cover with the dial ring so that the generator will seat into
the five o’clock position and the four aligning lugs align with the corresponding
slots in the dial ring. (See Figures 16 and 17.)
2. Carefully slide the dial ring cover into the dial ring.
3. Hold the dial ring cover in place and tighten the two dial ring cover mounting
screws to the specified torque.
CUTTING AND INSTALLING THE SPINDLE
1. Ensure that the lock bolt is extended and remove the cam from the lock case.
2. Check the stepper motor gear positioning.
Note: To avoid unnecessary damage, always make sure that the motor gear
is in its proper detent position (see Figures 18 and 19) when inserting the drive
cam. If it is not, a pencil may be used to move it to the proper position. This
must be done with the lock bolt extended.
Figure 16 - Cable Guide Locators Figure 17 - Dial Ring Cover
Generator

11
3. Slide the spindle through the cam
and reinsert the drive cam assembly into
the lock case and the dial ring cover until
the spindle nut is snug against the cam
and the cam is seated against the lock
case. Note that the square portion of the
spindle must be aligned with the square
hole in the lock case.
Service Tip: If it becomes necessary to
remove and reinstall the spindle nut during
lock installation or maintenance, the drive
cam can be secured by carefully placing
a #1 Phillips screwdriver between the cam
and the lock case. (See Figure 20.)
4. Slide the dial hub onto the spindle,
turning the hub slightly to align the
generator drive gear teeth. Hold the drive
cam assembly in place while installing the
dial hub.
5. Snug down one setscrew to hold the dial
hub in place.
6. Mark the spindle flush to the dial hub.
7. Loosen the setscrew and remove the hub.
Alternate Method: Instead of removing
the hub, you may leave it on, using the hub
as a vise to hold the spindle while cutting.
8. Carefully cut the spindle so that it will be
flush to the dial hub after installation.
Caution: The spindle should not extend
past the dial hub once installed but may be
recessed up to 1/32 inch below the surface
of the hub. If it extends past the dial hub, it
must be filed to flush.
9. Remove all burrs from the end of
the spindle.
Figure 18 - Wrong Position Figure 19 - Proper Position
Spindle flush to
hub or recessed
up to 1/32"
Figure 22 - Spindle Flush
or Recessed
#1 Phillips Screwdriver
Figure 20 - Secure Drive Cam
Spindle Nut
Cam
Lock
Case
Figure 21 - Mark Spindle Flush
to Hub

12
INSTALLATION OF THE DIAL HUB AND DIAL
1. Apply lubricant to the hub
bearing surface.
2. While holding the drive cam and spindle
in their proper positions in the lock case
assembly inside the container, push the
dial hub assembly onto the spindle.
3. Make a bend in the dial hub locating
gauge at its midpoint. This will keep it
from acting as a spring as the hub is
positioned for locking to the spindle.
4. Place the Dial Hub Locating Gauge over
the spindle and between the dial hub
assembly and the bushing in the dial
ring cover. This sets up an initial 0.010
inch end play. (See Figure 24.)
5. Push the dial hub and the spindle
assembly toward each other. (See
Figure 25.) While maintaining
a constant pressure on them,
SECURELY tighten the setscrews in
the dial hub assembly to 17-20 inch-
pounds of torque (a minimum of 1 inch
deflection of the handle of the hex
key). Tighten the inner setscrew first.
Caution: Tighten in a downward
motion in case the hex key should break.
(Figure 26.)
6. Remove the dial hub locating gauge.
Figure 26 - Tighten Setscrews
Figure 24 - Place Gauge Between Dial
Hub & Bushing
Figure 23 - Apply Lubricant to Hub
Figure 25 - Maintain Pressure on
Spindle Assembly

13
7. Apply lubricant to the retaining ring on the dial hub assembly and position the
retaining ring so that an equal amount of it is consistently exposed around the
hub. Also, apply grease from the lubricant tube to the entire ramp area just
inside the back of the dial and also to the inner surface of the 5-sided formed
clutch spring within the dial. (See Figures 27 and 28.)
Note: Ensure that the retaining ring
gap is aligned with the setscrews and that
an equal amount of the retaining ring is
exposed around the hub so the dial can
slide easily into place on the hub without
interference from the retaining ring. (See
Figure 29.)
8. Ensure that the 5-sided flat spring is
fully recessed in the dial with the spring
gap aligned with the internal key of the
dial. (See Figure 30.)
9. Carefully align the dial assembly such that the 5-sided formed spring matches
the flats of the dial hub assembly. Holding the dial square to the spindle, apply
pressure to the dial until the retaining ring seats in the dial. (See Figure 31.)
Note: You should not be able to pull the dial away from the dial hub assembly.
The dial clutch should provide a slip torque of 7 to 25 inch pounds.
Setscrews
Retaining Ring Gap
Figure 28 - Apply Lubricant Inside DialFigure 27 - Apply Lubricant to
Ret. Ring
Figure 30 - 5-Sided Flat Spring in Dial Figure 31 - Apply Pressure to Dial
Figure 29 - Align Retaining Ring

14
ATTACH BACK COVER ASSEMBLY FOR TESTING
1. Install the back cover assembly with the two mounting screws in order to test
the operation of the lock. Do not install the cover lock pin at this time.
Caution: Take care to align the connectors and the baffle to the hole in
the cover.
2. Verify the operation of the lock as described on the following page under
INSTALLATION COMPLETION CHECKLIST.
FINAL INSTALLATION OF THE BACK COVER ASSEMBLY
WARNING: Failure to verify that the lock
is operational before installing the cover
lock pin assembly may cause a lock out
condition.
1. Open the lock. (See page 15 for
operating instructions.) Leave the bolt in
the fully retracted position and remove
the back cover assembly.
2. Insert the cover lock pin through the back
cover.
3. Install the cover lock spring and retainer
clip onto the cover lock pin. The “fingers”
of the retainer clip should be angled away from the cover lock spring, and the
retainer clip must be seated in the groove of the cover lock pin. (See Figure 32.)
Helpful Hint: A small hammer and the cut off piece from the inner tube can
be used to install the spring and clip.
Caution: Do not push the clip retainer past the small groove in the cover
lock pin. If the clip is not located in the pin groove, it can interfere with pulling
the bolt or prevent withdrawal of the pin for normal back cover removal.
4. Record the 6-digit lock serial number in a secure location if you are the
end-user. If you are not the end-user, allow the end-user to remove the serial
number sticker from the back of the lock when the container has been placed
in use.
5. Make sure the bolt is fully retracted and reinstall the back cover with the cover
lock pin in place.
Caution: Take care to align the connectors, the baffle to the hole in the
cover, and the cover lock pin to the keyhole slot in the bolt rack.
6. Tighten the mounting screws to the specified torque.
7. After restoring the bolt to the extended position, verify that the cover lock pin is
fully recessed into the back cover. If not, gently wiggle the cover lock pin to
seat it.
Lock On Back
Cover Pin
Retainer
Clip
Cover Lock
Spring
Figure 32 - Back Cover Assembly

15
INSTALLATION COMPLETION CHECKLIST
1. Does the dial turn freely without scraping or binding?
2. Have all screws been securely tightened?
3. Operate the lock using the preset factory combination of 50-25-50. See the
following section: OPEN AND CLOSE THE X-09.
OPEN AND CLOSE THE X-09 (FACTORY COMBINATION)
CW=Clockwise; CCW=Counterclockwise
Note: The viewing angle of the LCD is restricted from either side as a
security feature of the lock. This feature restricts viewing of combination
dialing by the casual observer. The display may also appear slightly more
dim than previous versions of the X-0 series of locks.
TO OPEN THE LOCK (using the Factory Combination):
1. Dial left (CCW) until lock is “powered”. The lock is considered “powered” when
numbers appear on the LCD display screen.
2. Continue dialing left (CCW) to the first number of the factory combination, 50.
Stop on 50 and pause briefly.
3. Dial right (CW) to the second number of the factory combination, 25. Stop on
25 and pause briefly.
4. Dial left (CCW) to the first number of the factory combination, 50. Stop on 50
and pause briefly.
5. Dial right (CW). After OP with a right arrow (OPen right) is displayed, dial to the
right to retract the lock bolt.
Note: If at any time the dial remains stationary for more than 40 seconds,
the lock will reset (LCD will go blank) requiring the operator to redial the
entire combination.
TO CLOSE THE LOCK:
1. Turn Dial to the left (CCW) a minimum of one complete revolution to extend
the bolt.
2. Turn Dial to the right (CW) a minmum of one complete revolution to ensure that
it is locked.
Note: The Dial should turn freely in either direction without catching or
binding when the bolt is extended and the container is locked.

16
APPENDIX A
TUBE RETAINER POSITIONS
The tube retainer must be positioned so the cables come through the notch in
the retainer.
NOTCH

17
APPENDIX B
CABLE ROUTING DIAGRAMS
Refer to the following table and diagrams for suggested cable routing paths to avoid
pinching or rubbing of cables. Choose the diagram that most closely represents the
thickness of the container door with which you are working. Ensure that the cables are
routed so that they do not get pinched by the generator.
Door Thickness Cable Exit Position Bolt Position
4 1/2"
2 1/2"
3/4"
3
1
2
Left
Right
Down

18
APPENDIX C
SMALL SPINDLE HOLE INSTALLATION
FUNCTION OF THE INNER AND OUTER TUBES
The tubes of the X-09 protect the cables from mechanical abrasion. The inner tube
is positioned between the cables and the spindle while the outer tube is positioned
between the cables and the holes through the hardplate and container skin. The outer
tube also protects the cables in terms of electromagnetic radiation, preventing signals
coming from the lock and shielding the lock from external signals sent to it.
CONTAINERS WITH SMALL SPINDLE HOLES
Some GSA approved containers have spindle holes that are too small for the outer
tube of the X-09 to pass through. Usually, these are Mosler containers manufactured
between late 1986 and October 1990. The approved method of installing an X-09 in
such containers is similar to the method for installing an X-07. The outer tube is cut very
short, its flared end rests on the face of the container, and its non-flared end seats in
the tube retainer on the dial ring assembly. The outer tube must be installed in this
manner. It may not simply be omitted.
PREPARE & INSTALL TUBES
For small spindle hole installation, start the installation of the lock as you would
normally by following the instructions in the Installation manual through Step 2 of the
section entitled “PRELIMINARY LOCK INSTALLATION”. After completing Step 2 of
that section, proceed with the following instructions to prepare and install the inner
and outer tubes.
1. Place the flared end of the outer tube over the spindle hole on the outside face
of the container.
Note: On some containers the outer tube will actually be placed on an
extension of the hardplate box that is built into the container.
2. 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. 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. 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.