Kaba Mas High Security Pedestrian Exit Device with Electric Locking Trim Installation Manual
INSTALLATION GUIDE
High Security Pedestrian Exit Device
with Electric Locking Trim
WARNING: Kaba Mas locks are well protected from Electrostatic Discharge (ESD) damage once
they are installed, but can be damaged during the installation process if proper
precautions are not observed. Follow these precautions to avoid ESD damage when
installing the lock:
• Do not touch the end of the flex cable if the ESD protective cover has been
removed.
• Remove the X-09 lock cover assembly before touching the end of the flex cable.
• For the best protection, use an ESD wrist band grounded to the lock during
installation.
• The lock is protected to greater than 25,000 V when correctly installed.
TRADEMARKS
The following items are trademarks or registered trademarks of the Kaba Mas in the United States and/or
other countries.
• PowerStar
•X-09
Table of Contents
INTRODUCTION ........................................................................................................... 1
Installation Overview ............................................................................................................... 1
Basic Tools and Materials Needed .......................................................................................... 1
Door Handing .......................................................................................................................... 2
Templates ................................................................................................................................2
Rim Exit Device ....................................................................................................................... 2
CDX-09 Lock Assembly .......................................................................................................... 2
Dial Ring Mounting Template .................................................................................................. 2
PARTS CHECK .......................................................................................................... 3
Packaging................................................................................................................................3
Rim Exit Device Box ............................................................................................................... 4
CDX-09 Box ............................................................................................................................ 6
Lock Parts for Installation ....................................................................................................... 6
Installation Kit Contents .......................................................................................................... 6
ELECTRIC LOCKING TRIM SPECIFICATIONS ...................................................................... 7
RDS - Power Supply Control Module ......................................................................................7
DOOR PREPARATION................................................................................................... 8
Mark Rim Exit Device and Strike Locations ............................................................................ 8
Rim Exit Device Template ....................................................................................................... 9
Install CDX-09 Lock Strike ......................................................................................................9
CDX-09 Lock Assembly Template ........................................................................................ 10
Drill Holes for Rim Exit Device and Outside Lever Trim ........................................................ 10
Drill Holes for CDX-09 Lock Assembly ................................................................................. 10
CDX-09 Dial Ring Mounting Template ................................................................................... 10
RIM EXIT DEVICE / OUTSIDE LEVER TRIM ..................................................................... 11
Hardware Preparation ........................................................................................................... 11
Cut Lever Spindle and Rim Cylinder Tailpiece to Length ..................................................... 11
Determine Rim Exit Device Length, Cut to Length and Drill End Cap Mounting Hole ........ 11
Installation ............................................................................................................................. 13
Mount Rim Exit Device and Outside Lever Trim ................................................................... 13
Mount Strike .......................................................................................................................... 14
ELECTRIC LOCKING TRIM & RDS INSTALLATION ........................................................... 15
Installation Procedure ............................................................................................................ 15
System Schematic ................................................................................................................15
RDS-2 Specifications ............................................................................................................16
Operational Test for FSE (Fail Secure) Devices .................................................................... 16
HIGH SECURITY PEDESTRIAN DOOR LOCK INSTALLATION ................................................ 17
Preliminary Lock Installation.................................................................................................. 17
Cutting the Tubes ...................................................................................................................18
Installation of the Lock ........................................................................................................... 19
Installation of the Dial Ring ....................................................................................................20
Installation of the Cables ....................................................................................................... 20
Installation of Generator Cable and Cable Guides ................................................................ 21
Installation of the Dial Ring Cover ......................................................................................... 21
Cutting and Installing the Spindle .......................................................................................... 21
Installation of the Dial Hub and Dial ....................................................................................... 22
Attach Back Cover Assembly for Testing .............................................................................. 24
Final Installation of the Back Cover Assembly ...................................................................... 25
INTERFACE HARDWARE, COVERS ................................................................................ 25
Cable Assemblies .................................................................................................................25
Install Lock Cable Assembly ................................................................................................. 25
Install Bellcrank Cable Assembly .......................................................................................... 26
Connect Cable Assemblies ................................................................................................... 27
Adjust Cable Length .............................................................................................................. 28
Covers .................................................................................................................................. 29
Install Chassis Cover ............................................................................................................ 29
Install Lock Cover.................................................................................................................. 29
INTRODUCTION
Installation Overview
The High Security Pedestrian Exit Device - Electric Trim Version consists of:
1. A Rim Exit Device with Electric Locking Trim and Outside Lever Trim with Rim Cylinder
2. A High Security Pedestrian Door Lock (CDX-09)
3. Interface Hardware, Covers and Cover Brackets
4. A Relatching Delay System (RDS) with power supply and control module
The Installation Guide will describe the steps required to install each of these components of the High
Security Pedestrian Exit Device.
Basic Tools and Materials Needed
Before beginning installation, be certain that you have the following tools readily available:
• Measuring tape
• Level
• Combination square
• Tape
• Hammer
• Center punch
• Electric hand drill
• 1/4” drill bit
• 9/32” drill bit
• 5/16” drill bit
• 3/8” drill bit
• 1/2” drill bit
• No. 25 drill bit
• 2” hole saw with 1/4” pilot
• 1 1/4” hole saw with 1/4” pilot
• Long nose pliers
• Pliers
• 3/4” end wrench
• 1/4” end wrench
• Hacksaw
• File
• 1/4” or smaller slotted head screwdriver
• #1 Phillips head screwdriver
• #3 Phillips head screwdriver
• #1 Phillips head stubby screwdriver
• Safety glasses
Other tools that may be required:
• #10-24 Screw cutter
• External snap ring pliers
For a metal door installation, the following tools are needed:
• Tap handle
• #10-24 tap
• #10-32 tap
1
Door Handing
Determine whether the door is left hand reverse (LHR) or right hand reverse (RHR) by referring to Figure 1.
Note: Installer must insure that the door meets all building, fire and security code requirements prior to
installing the High Security Pedestrian Exit Device.
Figure 1 - Door Handing
Ensure that the Exit Device you are installing is compatible with the handing (LHR or RHR) of the door.
Templates
Rim Exit Device
A template is provided for the appropriate door installation (LHR or RHR) to assist in (1) laying out hole
locations for mounting the Rim Exit Device, (2) locating the lock horizontal centerline, and (3) locating the
lock strike top and bottom mounting hole centerlines. Ensure that the template is the correct one for the
handing of the door.
CDX-09 Lock Assembly
A separate template is included to assist in laying out the hole locations for the CDX-09 lock assembly. This
template is positioned on the inside of the door as described in the “CDX-09 Lock Assembly Template”
section.
Dial Ring Mounting Template
An additional template is provided as an aid for locating, drilling, and tapping the dial ring mounting screw
holes relative to the spindle hole. This template is positioned on the outside of the door as described in the
“CDX-09 Dial Ring Mounting Template” section.
2
PARTS CHECK
Packaging
The High Security Pedestrian Exit Device - Electric Trim Version is packaged in three boxes:
1. The Rim Exit Device Box contains:
• Rim Exit Device with associated parts and mounting hardware
• Outside Lever Trim with Rim Cylinder Lock and mounting hardware
• Interface Hardware, Covers and Cover Brackets with mounting hardware
2. The CDX-09 Box contains:
• High Security Pedestrian Door Lock (CDX-09)
3. The RDS Box contains:
• RDS-2 Power Supply Control Module
See the following sections for detailed part contents of the Rim Exit Device and CDX-09 boxes. The RDS-2
is the only item contained in the third box
3
Rim Exit Device Box
F-490 STRIKE
(1 QTY.)
4
RIM CYLINDER
MOUNTING BRACKET
Rim Exit Device Box (continued)
OR
OR
5
CDX-09 Box
Lock Parts for Installation
1. CDX-09 Dead bolt lock assembly
2. CDX-09 base hardplate
3. Dial hub assembly
4. Strike kit (type 2)
5. Spindle
3. Dial assembly
7. Dial ring assembly
Installation Kit Contents
1. Blade, saw (52 teeth/inch)
2. Handle, saw
3. Tube, outer
4. Tube, inner
5. CDX-09 to door mounting screws, pan
head #10 x 1.25, Type AB (6)
5. Dial ring attaching locknuts, #8-32 (2).
(Packaged with and used with exterior
mounting plate)
6. Rubber vise clamp
7. Lubricant.
8. Gage, dial hub locating
9. Zebra Connector and Retainer
10. Cable Tie Clips (3)
11. Dial ring to door mounting screws, pan head #8 -32 X 1.0 Type AB (2).
12. Cover Lock Pin Clip
13. Cover Lock Spring
14. Cover Lock Pin
15. Stone, deburring
16. Hexkey (5/64")
6
ELECTRIC LOCKING TRIM SPECIFICATIONS
The Electric Locking Trim (ELT) feature is available from Kaba Mas as a Special Engineering request (SER)
based on the Model 1000 High Security Pedestrian Exit Device. This feature includes a Relatching Delayed
System (RDS) with power supply and control module.
The ELT feature provides control capabilities of trim lock/unlock by a guard or security system while allowing
free egress at all times. The ELT system can be activated to hold the trim unlocked momentarily or for
extended periods of time.
The ELT feature can be interfaced with automatic doors, card readers, automatic fire alarm systems, etc.
The ELT application requires the use of the RDS control module. For details on the RDS, see the section
below. Closing the normally open dry contact retracts the latch. Opening the normally open switch returns the
latch to the locked position.
RDS - Power Supply Control Module
The RDS, when energized by pressing the dry contact switch, will activate the first ELT device and one
second later, will activate a second ELT device. Please note that for each RDS, two ELT devices can be
controlled by one switch.
Notes:
1. Each RDS comes in a 6” x 6” x 4” NEMA rated box.
2. RDS weight is 8 lbs.
3. The RDS-2 specifications and wiring schematic can be found in the Electric Locking Trim & RDS
Installation section of the manual.
7
DOOR PREPARATION
Mark Rim Exit Device and Strike Locations
Note: Door must be fitted and hung properly before proceeding.
1. With the door closed, establish the Rim Exit Device horizontal reference centerline by measuring 40-1/4”
from the finished floor surface.
Note: The 40-1/4” distance from the finished floor surface to the Rim Exit Device horizontal reference
centerline is a suggested distance, and may be varied to meet application requirements. However,
in no case should this distance be greater than 48” due to National Fire Protection Association code
requirements.
LHR SHOWN
Figure 2 - Establish Rim Exit Device Horizontal Reference Centerline
2. Using a level, draw a horizontal line on the door
as shown in Figure 2. Transfer the Rim Exit
Device horizontal reference centerline to the
door jamb stop face.
3. Establish the Rim Exit Device vertical reference
centerline by measuring 2-1/4” from the face of
the door jamb stop along the Rim Exit Device
horizontal reference centerline as shown in
Figure 3. Using a level, mark the Rim Exit
Device vertical reference centerline on the door
approximately 13½ inches above and 9½
inches below the Rim Exit Device horizontal
reference centerline as shown in Figure 4.
Figure 3 - Establish Rim Exit Device Vertical Reference Centerline
8
Rim Exit Device Template
1. Position the Rim Exit Device
drilling template on the inside of
the door using the Rim Exit
Device horizontal and vertical
reference centerlines previously established and shown in
Figure 4. Tape the template to
the door.
2. Center punch all hole positions
onto the door.
Note: It is very important to
accurately center punch all
holes since hole locations
establish the distance between the Rim Exit Device
and the CDX-09 lock assembly.
3. Transfer the lock horizontal reference centerline from the Rim Exit Device template to the door and door
jamb. This centerline will be used to position the CDX-09 lock assembly drilling template on the door, and
locate the center mounting hole for the strike.
Figure 4 - Door Layout for Rim Exit Device
4. Transfer the lock strike mounting hole centerlines from the Rim Exit Device template to the door jamb. These
centerlines will be used to position the CDX-09 strike in the correct vertical location on the door jamb.
Install CDX-09 Lock Strike
1. Horizontal positioning of the CDX-09 lock
assembly drilling template is referenced to the
CDX-09 lock strike, so this strike must be
installed before the CDX-09 lock assembly
template can be positioned on the door. #10-32
machine screws are recommended for a metal
door jam and #10 thread forming screws are
recommended for a wood jamb.
2. Position the CDX-09 lock strike on the door
jamb face as shown in Figure 5. Align the strike
vertically so that the top and bottom strike
mounting counterbored holes are centered
over the lock strike mounting hole centerlines.
Align the strike horizontally so that the strike
edge adjacent to the open tang is 3/32” from
the door jamb stop.
3. Center punch the two slotted strike hole
locations (mid-slot) onto the door jamb face.
4. Drill and tap the two (2) slotted hole locations
for attaching screws. (No. 25 drill, 0.149 inch diameter for #10 thread forming screw. No. 21 drill, 0.159 inch
diameter for #10-32 machine screw).
Figure 5 - CDX-09 Strike Installation
5. Mount the strike to the door jamb face using two (2) #10-32 pan head machine screws for the two slotted
holes.
6. Install the remaining 3 flat head (machine or thread forming) screws after mounting the CDX-09 lock
assembly and the rim exit device.
9
CDX-09 Lock Assembly Template
1. Fit the CDX-09 strike tang opening of the CDX-09 lock assembly cardboard drilling template over the strike
tang mounted on the door jamb face. Center the strike tang opening of the template horizontally over the
strike tang as shown in Figure 6.
2. Position the lock template on the inside of the door
and align the lock horizontal reference centerline on
the lock template with the lock horizontal reference
centerline on the door. Tape the template to the door.
Note: The door must be ajar and free to swing while
positioning the template to the strike tang and
door.
3. Center punch all hole positions onto the inside door
surface.
Note: It is very important to accurately center punch all
holes since hole locations establish the distance
between the Rim Exit Device and the CDX-09
lock assembly.
4. Remove CDX-09 Lock Assembly Template and the Rim Exit Device Template.
Figure 6 - CD-X09 Lock Assembly Template
Placement
Door Preparation for Rim Exit Device and Outside Lever Trim
1. Using information on the Rim Exit Device template, drill holes and cut rectangular opening as directed.
Drill Holes for CDX-09 Lock Assembly
1. Drill the 0.5 inch diameter spindle hole 1.25 inches deep. DO NOT drill through the door.
2. Drill all six CDX-09 attaching screw holes (No. 25 drill, 0.149 inch diameter). Drill the holes 1.25 inches deep.
DO NOT drill through the door.
CDX-09 Dial Ring Mounting Template
1. Using a square or level, transfer the lock horizontal reference centerline from the inside door surface to the
outside door surface.
2. Establish the center of the spindle hole on the outside door surface as follows:
A. On the inside door surface measure the horizontal distance from the edge of the door to the center of
the 0.5- inch spindle hole.
B. Establish the spindle hole center on the outside door surface by measuring this distance from the
edge of the door (compensating for the door edge bevel, if necessary) along the lock horizontal
reference centerline and mark vertical centerline for 1 inch in each direction.
C. Mark horizontal line so as not to extend beyond dial ring.
3. Center punch the hole position onto the outside of the door and drill the 0.5-inch spindle hole through the
door.
4. Align the CDX-09 dial ring mounting template on the outside door surface with the lock horizontal reference
centerline and the 0.5-inch spindle hole. Tape the template to the door.
5. Center punch the dial ring mounting hole positions (either the horizontal or vertical set of holes) onto the
outside of the door, and remove the template.
6. Drill two (2) attaching screw holes (No. 29 drill, 0.136 inch diameter) 1.25 inches deep.
the door.
7. Tap two (2) #8-32 holes, if required.
10
DO NOT drill through
RIM EXIT DEVICE / OUTSIDE LEVER TRIM
Hardware Preparation
Before installing the Rim Exit Device and Outside Lever Trim, it is necessary to:
1. Cut Lever Spindle and Rim Cylinder Tailpiece to length.
2. Determine Rim Exit Device length required and cut device to length and drill.
Note: The electric locking trim fail secure rim device cannot be re-handed.
Details on each of these items follow.
Cut Lever Spindle and Rim Cylinder Tailpiece to Length
1. Position the outside lever trim on the door and measure the Lever Spindle and Cylinder Tailpiece as they
extend through the door.
2. If necessary, cut the Lever Spindle to extend beyond inside face of door by 5/8”.
3. If necessary, cut the cylinder tailpiece to extend beyond inside face of door by 5/16” - 3/8”.
Determine Rim Exit Device Length, Cut to Length and Drill End Cap Mounting Hole
1. Determine the Rim Exit Device length.
Figure 7 - Rim Exit Device Length Calculation
A. Locate the Rim Exit Device vertical reference centerline on the door.
B. Measure the distance “Y” from the Rim Exit Device vertical reference centerline to the door jamb stop
surface on the hinge side.
C. Subtract 1” for recommended clearance.
D. Length of Rim Exit Device from vertical reference centerline “X”.
11
2. If the Rim Exit Device is longer than “X”, cut the device.
A. Remove the device channel cover, ro-
tate 180 degrees, and then re-insert it.
(U-shaped slot towards touchbar.)
B. Mark the device channel and channel
cover to length “X”.
Note: Be sure channel cover is pushed snug to
touchbar prior to marking or cutting to
size.
Figure 8 - Mark Device Channel and Cover Length
C. Cut both device channel and channel cover to
marked dimension and remove burrs.
Note: Factory recommends sawing rather than grind cut
to size. Grinding can damage the finish of the
device and sawing results in less damage to the
device finish.
3. Drill end cap mounting hole in device
channel.
A. Remove the device channel cover
and drill a 5/16” diameter hole on the
device reference centerline 5/16”
from the end of the channel as shown
in Figure 10.
Figure 9 - Cut Device Channel and Cover
Figure 10 - Drill End Cap Mounting Hole in Device Channel
12
Installation
Mount Rim Exit Device and Outside Lever Trim
1. Insert Rim Cylinder into trim plate and secure on opposite
side of trim with mounting bracket and two screws as
shown in Figure 11. Tighten screws securely.
Note: The Rim Cylinder Mounting Screws may need to be
shortened. You may discard the mounting plate that
was included with the Rim Cylinder as it is not needed
for this installation.
2. Place Outside Lever Trim on door using holes previously
drilled.
3. Throughbolt the Rim Exit Device to the Outside
Lever Trim using four (4) #10-24 x 1” PPHMS
as shown in Figure 12. Do not tighten screws.
4. Locate, mark and drill end cap mounting hole
following these steps:
A. Level the Rim Exit Device
B. Mark the center of the 5/16” diameter hole
at the end of the channel.
C. Drill a 9/32” diameter hole through the door.
D. Drill a 3/8” diameter hole on the trim side
of the door using the 9/32” diameter hole
as a guide.
Mounting
Bracket
Tailpiece
Rim
Cylinder
Figure 11 - Rim Cylinder Mounting
6. Insert the device channel cover as shown in
Figure 13, with the U-shaped slot toward the
open end.
7. Install the end cap mounting bracket using the
sexbolt and the 1/4”-20 x 3/4” TPHMS mounting screw as shown in Figure 13. Make sure
the Rim Exit Device is level.
Tighten the mounting screw.
8. Tighten all mounting screws and
check for smooth operation.
1/4”-20 X 3/4” TPHMS
MOUNTING SCREW
Figure 13 - Install End Cap Mounting Bracket
Figure 12 - Mount Rim Exit Device
Through Door to Outside Lever Trim
CHANNEL
COVER
SEX
BOLT
MOUNTING
BRACKET
13
9. Attach the channel end cap using two #8-32 x 3/
8” UFPHMS with nylon patch as shown in Figure
14.
Mount Strike
Figure 14 - Install Channel End Cap
1. Ensure that the Rim Exit Device centerline has been transferred to the door jamb stop.
2. Refer to Figure 15. Center strike on door jamb
stop across Rim Exit Device reference
centerline and flush to door surface.
3. Mark top and bottom screw locations, then
center punch and drill (and tap if required) for
mounting screws.
4. Apply strike to door jamb stop using two #10-24
x 3/4” FPHMS screws.
5. Check Rim Exit Device for smooth operation
and secure latchbolt engagement. Adjust strike
if required.
6. For third (center) mounting screw on strike,
mark location, center punch, drill (and tap if
required) hole. Use a #10-24 x 3/4” FPHMS
screw to mount.
Figure 15 - Mount Rim Exit Device Strike
14
ELECTRIC LOCKING TRIM & RDS INSTALLATION
Installation Procedure
1. Install ELT devices per device installation instructions.
2. Install power supply (RDS-2). See Wire Guage Chart below.
3. Complete wiring as indicated on System Schematic.
Caution: Ensure that cover is secured on RDS-2 box before applying 115 VAC power.
4. Test operation of ELT devices. (Refer to RDS-2 Specifications on next page.)
System Schematic
15
RDS-2 Specifications
• Solenoid rated for continuous duty (with RDS).
• Input voltage required: 115 VAC, 60 Hz, 5 amps to transformer.
• Output voltages:
- First Device: Terminal #1 and #2; 24V DC impulse; 5V DC continuously after impulse.
- Second Device: One second delay after first device; Terminal #3 and #4; 24V DC impulse; 5V DC
continuously after impulse.
• Dip switch (when on) will hold device(s) retracted for set time period as indicated below:
DIP # 123 4 5 6
Hold Time (seconds) 248163264
• DIP switches moved to the ON position have a hold time of all ON settings added together. Example:
DIP #1 and #2 = 6 seconds hold time. A hold time of less than 4 seconds (DIP #1 only) is not
recommended.
• For continuous ELR retraction, turn all DIP switches to OFF position and apply a jumper or other
source switch to terminal #7 and #8.
• A green flashing LED indicates that power is applied to the board. A solid green LED indicates that
the device(s) are being retracted. An orange LED indicates that the devices are being held in the
retracted position. A flashing red LED indicates a short in the wiring between the board and device.
Operational Test for FSE (Fail Secure) Devices
1. With power engaged, the trim will be unlocked.
2. Function the control device or disconnect main power from the RDS-2, the trim will lock.
3. With power disengaged, the trim will be locked. Check to ensure that the key-override feature functions
properly by unlocking the trim.
16
HIGH SECURITY PEDESTRIAN DOOR LOCK 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.
Thermal
Relocker
Actuator
3. Remove the protective casing from the end of the cables.
4. Refer to Figure 16. 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. 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.
5. Place the 3.5 x 5 x 1/8 inch hardplate against the back of the CDX-09 lock case assembly.
6. Feed the cables and outer tube through the 0.5 inch hole in the door while positioning the CDX-09 and
hardplate against the door. Insert and tighten slightly two #10-32 screws nearest the strike opening (top and
bottom) to attach the CDX-09 and hardplate to the door.
Drive Cam
Assembly
Inside Lock Case Assembly
Figure 16 - Tube-Cable Assembly Relationships
17
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.
7. Loosely attach the lock case assembly to the container wall with two of the four mounting screws, placing
them diagonally across from each other.
8. Tighten the lock case mounting screws to hold the lock case in place.
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. 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. 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.
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.
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.
Remove the inner tube and cut by the same method as described
in Step 5.
Assemble Saw
Cut Tube Using Vise
18
Deburr Tubes
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.
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. Be
careful to keep the cables pulled taut while seating the tube to avoid
pinching and damaging them.
Inner and Outer Tubes
Seat Inner Tube in Retainer
3. Refer to Figure 17. 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. 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
Figure 17 - Tube-Cable Assembly Relationships
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. Place the 3.5 x 5 x 1/8 inch hardplate against the back of the CDX-09 lock case assembly.
5. Feed the cables and outer tube through the 0.5 inch hole in the door while positioning the CDX-09 and
hardplate against the door. Insert and tighten slightly two #10-32 screws nearest the strike opening (top and
bottom) to attach the CDX-09 and hardplate to the door.
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.
6. Loosely attach the lock case assembly to the container wall with two of the four mounting screws, placing
them diagonally across from each other.
7. Verify that the lock case assembly is centered with respect to the Horizontal Reference centerline of the
lock.
8. Tighten the lock case mounting screws to hold the lock case firmly in place.
19
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. 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.
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.
Seal Cover
ZIF Connectors
Closed
Open
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
Open ZIF Seal Cover Closed & Open ZIF Connectors
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.
20
LCD and ZIF connectors
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.
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.
4. Install at least one of the stick-on cable guides in an appropriate position
to restrain the cables.
5. Route the cables through the cable guide that was just installed.
6. Depending on the thickness of the container,
additional cable guides
may be necessary to
ensure the cables are
sufficiently restrained. 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
Cable Guide Locators
Dial Ring Cover
through the dial ring
cover.
CONNECTOR
HOUSINGIS
Zebra Assembly
ZEBRA
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.
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.
21
Note: To avoid unnecessary
damage, always make
sure that the motor gear
is in its proper detent
position 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.
Wrong Position
Proper Position
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.
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.
Lock
Spindle Nut
Case
Cam
#1 Phillips Screwdriver
Secure Drive Cam
Mark Spindle Flush to Hub
Spindle flush to
hub or recessed
up to 1/32”
9. Remove all burrs from the end of the spindle.
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 gage at its midpoint. This will keep
it from acting as a spring as the hub is positioned for locking to the
spindle.
22
Spindle Flush or Recessed
Apply Lubricant to Hub
4. Place the Dial Hub Locating
Gage 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.
5. Push the dial hub and the
spindle assembly toward
each other. While maintaining a constant pressure on
Place Gage Between Dial Hub &
Bushing
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.
6. Remove the dial hub locating gage.
Maintain Pressure on Spindle
Assembly
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.
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.
8. Assure the the 5-sided flat spring is fully recessed in the dial with the
spring gap aligned with the internal key of the dial.
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.
Tighten Setscrews
Apply Lubricant Inside Dial Apply Lubricant to Ret. Ring
Retaining Ring Gap
Setscrews
Align Retaining Ring
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.
5-Sided Flat Spring in Dial
Apply Pressure to Dial
23
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.
3. Check the operation of the lock by verifying the following:
• Ensure that the dial turns freely without scraping or binding.
• Ensure that all screws have been securely tightened.
• Dial the combination (it has been factory set to 50-LEFT, 25-RIGHT, 50-LEFT). Your lock should dial
freely without scraping or rubbing and should open when the correct combination has been dialed.
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. 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 On Back
Cover Pin
lock spring, and the retainer clip must be seated in the groove of the
cover lock pin.
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.
Cover Lock
Spring
Back Cover Assembly
Retainer
Clip
4. Record the lock serial number in a secure location.
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.
24
INTERFACE HARDWARE, COVERS
Cable Assemblies
These steps involve attaching the two stainless steel mechanical cable assemblies to the lock and Rim Exit
Device chassis, respectively; connecting these cable assemblies; and adjusting the cable length to achieve
proper timing of the high security lock bolt retraction relative to the Rim Exit Device latchbolt.
Install Lock Cable Assembly
1. Locate the correct lock cable assembly
needed for the handing of your installation. The bag labeled with part number
114048 contains the LHR lock cable assembly. The bag labeled with part number 114047 contains the RHR lock cable
assembly. The lock cable assembly has
a brass ball-end plug on one end and a
turnbuckle secured by a brass ball-end
plug on the other end.
Note: The LHR lock cable assembly is
approximately 1/4 inch shorter than the
RHR lock cable assembly.
2. Detach the lock pulley cover from the pul-
ley assembly by removing the #6-32 x
1/4” flat head screw.
3. Refer to Figure 18 or Figure 19 depend-
ing on the handing of your installation.
Insert the brass ball-end plug of the lock
cable assembly into the face of the lock
pulley and thread the cable counterclockwise around the pulley. Position the lock
pulley cover over the locating pin on the
pulley and secure the cover to the pulley
with the #6-32 x 1/4” flat head screw.
Figure 18 - Lock Cable Assembly - RHR
Figure 19 - Lock Cable Assembly - LHR
25
Install Bellcrank Cable Assembly
1. Locate the bellcrank cable assembly. It has a strap fork secured by a ball and shank on one end and
a brass threaded plug with a brass nut on the other end.
2. Refer to Figure 20 or Figure 21 depending on the handing of your installation. Spread the strap fork
over the upper bellcrank of the Rim Exit Device chassis and align the strap fork holes with the hole in
the bellcrank.
3. Secure the strap fork to the bellcrank using the #8-32 shoulder screw and #8-32 locknut. The shoulder
screw is inserted from the outside and the locknut is secured on the inside. Tighten the locknut until
it bottoms against the shoulder of the screw.
Figure 20 - Bellcrank Cable Assembly - RHR
Figure 21 - Bellcrank Cable Assembly - LHR
26
Connect Cable Assemblies
1. Refer to Figure 22 or Figure 23 depending on the handing of your installation. Move the brass nut away
from the open end of the brass threaded plug on the bellcrank cable assembly. Turn the brass threaded
plug into the turnbuckle on the lock cable assembly until approximately half of the threaded plug is
inside the turnbuckle.
2. Do not tighten the brass nut on the threaded plug at this time.
Figure 22 - Connect Lock and Bellcrank Cable
Assemblies - RHR
Figure 23 - Connect Lock and Bellcrank Cable
Assemblies - LHR
27
Adjust Cable Length
The effective cable length may be changed by turning the brass threaded plug into and out of the turnbuckle.
The cable length must be adjusted so that as the push bar of the Rim Exit Device is depressed, the CDX-09
bolt is fully retracted and latched back just before the Rim Exit Device latchbolt clears its strike. Refer to
Figure 24 and Figure 25 in preparation for adjusting the cable length. The proper sequence of adjustment is:
1. With the door open, slowly depress the push bar and determine if the CDX-09 bolt retracts and latches back
prior to maximum depression of the push bar. If the CDX-09 bolt does not retract and latch back, slightly
shorten cable and recheck.
2. Close the door and slowly depress the push bar until the Rim Exit Device latchbolt just clears its strike.
Check to see if the CDX-09 bolt is fully retracted and latched back at this point.
If not fully retracted and latched back: Shorten the cable length until the CDX-09 bolt retracts and latches
back just before the Rim Exit Device latchbolt clears its strike.
If fully retracted and latched back: With the door open, depress the push bar until the CDX-09 bolt retracts
and latches back. Depress the CDX-09 bolt reset latch to allow the CDX-09 bolt to extend. Check to see if the
pulley restores clockwise sufficiently to prevent the CDX-09 bolt from being pushed back. (A thin-blade
screwdriver may be inserted between the end of the bolt and the bolt guard for the purpose of pushing back
on the bolt.) If the CDX-09 bolt can be pushed back, slightly increase the cable length and recheck the CDX09 bolt latching status by following the directions in Step 2 above. If necessary, needle nose pliers may be
used to preset the “curl” to the pulley end of the cable.
3. Tighten the brass nut on the threaded plug against the turnbuckle.
9
9
99
Figure 24 - Position of CD-X09 Bolt Fully
Retracted and Latched Back
Figure 25 - Position of Latchbolt Just Prior to
Clearing Strike
4. Adjust the CDX-09 strike such that the throat of the strike has minimum clearance of the bolt guard when
the door is contacting the jamb.
5. Mark or transfer punch the locations of the remaining three (3) flat head screw locations for the CDX-09 strike.
Drill #21, 0.159 inch diameter and tap #10-32 to install flat head machine screws. (Dril #25, 0.149 inch
diameter to install flat head thread forming screws.)
28
Covers
Install Chassis Cover
1. Locate the chassis cover and plastic cover insert.
2. Orient the chassis cover as it will be installed, based on door handing, and slide the plastic cover insert into
the bottom of the chassis cover.
3. Position the chassis cover over the Rim Exit Device, aligning the cover cutouts to fit over the chassis.
Locate the cover flush to the surface of the door and bias the cover away from the door edge.
4. Secure the chassis cover to the Rim Exit Device chassis using four (4) #8-32 x 1/4” UFPHMS black flat
head screws.
Install Lock Cover
1. Locate the correct lock cover based on door handing. (Both a RHR and a LHR lock cover are included in
the Rim Exit Device box.)
2. Position the lock cover over the lock cover mounting brackets. Locate the cover flush to the surface of the
door and bias the cover away from the door edge.
3. Secure the lock cover to the lock cover mounting brackets using four (4) #8-32 x 1/4” UFPHMS black flat
head screws.
29
NOTES
Document Number 518.073
Rev. A - 01/04
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.
© 2004 Kaba Mas
All rights reserved
Kaba Mas Corporation
749 W. Short Street,
Lexington, KY 40508 USA
Phone: 859-253-4744 FAX: 859-255-2655
Customer Service: 800-950-4744
www.kaba-mas.com
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