Kaba Mas X-10 User manual

INSTALLATION
INSTRUCTIONS
X-10TM
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�������������������������������������������������������������������������������������������� 5
Installation of the Lock������������������������������������������������������������������������������������ 6
Installation of the Dial Ring����������������������������������������������������������������������������� 7
Installation of the Cables �������������������������������������������������������������������������������� 7
Installation of Generator Cable and Cable Guides ����������������������������������������� 8
Installation of the Dial Ring Cover ������������������������������������������������������������������ 9
Cutting and Installing the Spindle ������������������������������������������������������������������� 9
Installation of the Dial Hub and Dial ������������������������������������������������������������� 10
Final Installation�������������������������������������������������������������������������������������������� 12
Installation Completion Checklist������������������������������������������������������������������ 12
Open and Close the X-10 Lock (Factory Combination)�������������������������������� 13
Appendix A - Tube Retainer Positions������������������������������������������� 14
Appendix B - Cable Routing Diagrams������������������������������������������ 15
Document Number 519�0112
Rev� B - 10/13
Kaba Mas LLC
749 W� Short Street,
Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Technical Support: 800-950-4744
www�kaba-mas�com

1
INTRODUCTION
Please read all instructions before you install and use your Model X-10™ lock� This
will help you avoid unnecessary costs and issues 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atle
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-10 lock screws.
All other necessary tools and materials are provided.
X-10 LOCK PARTS FOR INSTALLATION
1. Lock Assembly
2. Dial Ring
Assembly
3. Dial Assembly
4. Spindle
5. Dial Hub
Assembly
12
3
5
4
TABLE OF RECOMMENDED TORQUES FOR THE VARIOUS X-10 LOCK SCREWS
Applications P/N Screw Size Torque (In�Lb�)
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
Spindle Screw 205056 6-32 9.0 to 11.0
Figure 1: X-10 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 (Two sets; 4 each, English and Metric)
9� Stick-on Cable Guides (3)
10�Zebra Connector & Zebra Connector Housing*
11� Lubricant (Lubriplate)
12�Dial Hub Locating Gauge
13�Hex Key (5/64")
14� Spindle Screw
*The Zebra Connector and Zebra Connector Housing are assembled at the factory but
may come apart during shipment�
Figure 2 - X-10 Installation Kit
1
10
14
11
2
312
4 5 6
13
9
8
7

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t
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 mounting holes. A Template of actual size is included with the lock
installation kit. Make sure to deburr the spindle hole and opening.
Figure 3: X-10 Drill Template

4
PREPARATION FOR NEW INSTALLATION OF THE LOCK
1� Use the template to establish the correct locations of all 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�
(M6X1, if Metric)
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�
Figure 4 - Tube-Cable Assembly Relationships

5
INSTALLATION
PRELIMINARY LOCK INSTALLATION
1� Deburr spindle hole and opening�
2� Feed Lock Cable through spindle hole�
3� Loosely attach the lock case to the
container wall with the four mounting
screws�
4� Tighten the lock case mounting screws
to hold the lock case in place� (See
Figure 5�)
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rmly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 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 6�) 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 into the rubber vise
clamp (provided), with the mark just
beyondtheclamp.Thenrmlyclamp
the rubber vise clamp in a vise� (See
Figure 7�) Use the saw to cut the tube
where marked�
Figure 6 - Assemble Saw
Figure 7 - Cut Tube Using Vise
Figure 5 - Tighten
Mounting Screws

6
Note: 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.
6� The inside and outside of the tubes must
be deburred after cutting� Use the stone
provided for this purpose� Make sure
there are no sharp edges on either tube
(inside and outside) that will damage the
cables� (See
Figure 8�)
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 9�) 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 the cutout in the
tube aligns with the cables and allows the tube to seat completely in the tube
retainer� (See Figure 10�)
2� Feed the cables through the outer tube
fromthearedend.Seatthetubeinto
position on the tube retainer on the back
of the lock case� (See Figure 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 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 to the container wall using the lock case
mounting screws�
5. Tightenthelockcasemountingscrewstothespeciedtorqueonpage1.
(Also see Figure 5�)
Figure 9 - Inner and
Outer Tubes
Figure 10 - Seat Inner Tube
in Retainer
Figure 8 - Deburr Tubes

7
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
9 on the previous page. 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 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 and place the dial ring
over the end of the tubes� Make sure the tubes are seated in the tube retainer
on the dial ring�
4� Attach the dial ring to the container with the dial ring mounting screws and
tightentothespeciedtorque.(SeePage1.)
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 11 and 12�)
2� Plug the cables into the ZIF connectors with the bright metal tabs facing toward
the circuit board� 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 of the seal cover�
Seal Cover
ZIF Connectors
Closed Open
Figure 11 - Open ZIF Seal Cover Figure 12- Closed & Open
ZIF Connectors

8
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vegoldtabs
must be visible�
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 into the
Zebra connector housing before proceeding�
CAUTION: The Zebra connector is an electrical
connector. Keep it clean!
3� Place the Zebra connector and connector
housing 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 the black
Zebra connector housing is positioned as
shown in Figure 14�
4� Install at least one of the stick-on cable
guides in an appropriate position to restrain
the cables� (See Figure 15 for possible locations�)
5� Route the cables through the cable guide that was just installed�
Figure 13 - LCD and ZIF Connectors
Figure 14 - Zebra Assembly

9
6� Depending on the thickness of the container, additional cable guides may be
necessary to ensure the cables are held in place� Some possible locations are
shown in Figure 15� Install additional guides as needed, and route the LCD and
generator cables through them to ensure 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�
Caution: 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thegeneratorwillseatintotheve
o’clock position and the four aligning lugs align with the corresponding slots in
the dial ring� (See Figures 15 and 16�)
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speciedtorque.(SeePage1.)
CUTTING AND INSTALLING THE SPINDLE
1� Slide the spindle into the lock case� Note the square portion of the spindle
must be aligned with the square hole in the lock case� Insert spindle screw and
tighten�
2� Slide the dial hub onto the spindle, turning the hub slightly to align the generator
drive gear teeth�
3� Partially tighten one setscrew to hold the dial hub in place�
4. Markthespindleushtothedialhub.(SeeFigure17.)
5� 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.
Figure 15 - Cable Guide Locators Figure 16 - Dial Ring Cover
Generator

10
6� Remove spindle screw and spindle from lock case prior to cutting� Carefully cut
thespindlesothatitwillbeush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. (See Figure 18.)
7� Remove all burrs from the spindle�
INSTALLATION OF THE DIAL
HUB AND DIAL
1� Slide the spindle into the lock case�
Note that the square portion of the
spindle must be aligned with the
square hole in the lock case� Insert
spindle screw and tighten� (For torque
specications,seePage1.)
2� Apply lubricant to the hub bearing
surface� (See Figure 19�)
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 and the bushing in the dial ring
cover� This sets up an initial 0�010
inch end play� (See Figure 20�)
5. Tightentheinnersetscrewrst.Now
SECURELY tighten the setscrews in
the dial hub to 17-20 inch-pounds of
torque(aminimumof1inchdeection
of the handle of the hex key)�
6� Remove the dial hub locating gauge�
Spindle flush to
hub or recessed
up to 1/32"
Figure 18 - Spindle Flush
or Recessed
Figure 17 - Mark Spindle Flush to Hub
Figure 19 - Apply Lubricant to Hub
Figure 20 - Place Gauge Between
Dial Hub & Bushing

11
Caution: Tighten in a downward motion in case the hex key should break. (See
Figure 21.)
7� Apply lubricant to the retaining ring on the dial hub� Position the retaining ring
so an equal amount of lubricant 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 to the inner surface of the 5-sided formed clutch spring within the
dial� (See Figures 22 and 23�)
Note: Ensure the “C” clip is located in the grove closest to the set screw. The
retaining ring gap should be aligned with the setscrews so an equal amount of the
retaining ring is exposed around the hub. The dial should slide easily into place on
the hub without interference from the retaining ring. (See Figure 24.)
8. Ensurethatthe5-sidedatspringisfullyrecessedinthedialwiththespring
gap aligned with the internal key of the dial� (See Figure 25�)
9. Carefullyalignthedialsothe5-sidedformedspringmatchestheats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 26�)
Note: You should not be able to pull the dial away from the dial hub assembly.
Figure 23 - Apply Lubricant
Inside Dial
Figure 22 - Apply Lubricant to
Ret. Ring
Figure 21 - Tighten Setscrews
Setscrews
Retaining Ring Gap
Figure 24 - Align Retaining Ring

12
FINAL INSTALLATION
Warning: Failure to verify that the lock is operational may cause a lockout condition.
1. Open the lock using the factory combination. (See Page 13.) Leave the bolt in
the fully retracted position.
2. Record the 8-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.
3. Make sure the bolt is fully retracted.
4. Tighten the spindle screw to the torque specifications. (See Page 1.)
INSTALLATION COMPLETION CHECKLIST
1� Does the dial turn freely without scraping or binding?
2� Have all screws been securely tightened?
3� The dial clutch should provide a slip torque of 7 to 25 inch pounds�
4� Operate the lock using the preset factory combination of 50-25-50� See the
following section: OPEN AND CLOSE THE X-10�
Figure 25 - 5-Sided Flat Spring
in Dial
Figure 26 - Apply Pressure to Dial

13
OPEN AND CLOSE THE X-10 (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.
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rstnumberofthefactorycombination,50.
Stopon50andpausebriey.
3� Dial right (CW) to the second number of the factory combination, 25� Stop on 25
andpausebriey.
4. Dialleft(CCW)totherstnumberofthefactorycombination,50.Stopon50
andpausebriey.
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� Wait 3 seconds�
2� Turn Dial to the right (CW) a minimum 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.

14
APPENDIX A
TUBE RETAINER POSITIONS
The tube retainer must be positioned so the cables come through the notch in the retainer�
NOTCH (SHOWN IN POSITION 3)
While facing the outside of the container, position the notch in the tube retainer as follows:
Bolt Position Notch Position
Up
Left
Down
Right
1
2
3
4
TUBE RETAINER

15
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� Ensure 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
Down
Up
Left

16
NOTES

17
NOTES

Document Number 519�0112
Rev� B - 10/13
Kaba Mas LLC
749 W. Short Street,
Lexington, KY 40508 USA
Phone: [phone] FAX: [phone]
Technical Support: 800-950-4744
www.kaba-mas.com
Notice: The information in this manual is subject to change without notice and
does not represent a commitment on the part of Kaba Mas. Kaba Mas shall not
be liable for technical or editorial errors or omissions contained herein; nor for
incidental or consequential damages resulting from the furnishing, performance
or use of this material.
© 2002-2013 Kaba Mas LLC
All rights reserved�