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INSTALLATIONINSTRUCTIONS

FOR THE

X-07/CEX-07HIGH SECURITY

ELECTRONIC LOCKTYPE 1F

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Table of Contents

INTRODUCTION ................................................................................... 3BASIC TOOLS AND MATERIALS NEEDED ................................... 3LOCK PARTS FOR INSTALLATION ................................................ 4INSTALLATION KIT CONTENTS ...................................................... 4TEMPLATE ..................................................................................... 5PREPARATION FOR NEW INSTALLATION OF THE LOCK ............ 6

INSTALLATION .................................................................................... 7INSTALLATION OF THE LOCK ....................................................... 7INSTALLATION OF THE DIAL RING ................................................ 8INSTALLATION OF THE TUBES AND SPINDLE ........................... 10INSTALLATION OF THE DIAL HUB AND DIAL .............................. 18

INSTALLATION COMPLETION CHECKLIST ..................................... 20RESETTING COVERT ENTRY AND COVERT ENTRY

COMBINATION CHANGE ............................................................. 21

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INTRODUCTIONPlease read all instructions before you install and use your Model X-07 lock.This will help you avoid unnecessary costs and concerns resulting from im-proper installation.

BASIC TOOLS AND MATERIALS NEEDED1. Small Phillip’s head screwdriver (#0)2. Medium Phillip’s head screwdriver (#1/#2)3. Standard hacksaw (32 teeth/inch)4. Small flat file5. Small vise

Recommended, but not required:6. Torque screwdriver (30 inch-pound capacity), or7 Standard torque wrench with screwdriver bits

Note: See table of recommended torques for the various X-07 lockscrews.

All other necessary tools and materials are provided.

TABLE OF RECOMMENDED TORQUES FOR THE VARIOUS X-07 LOCK SCREWS

Applications P/N Screw Size Torque (In.Lb.)Slide Retainer 105014 1-64 1.0 to 1.5Lever 105017 1/2-32 15.0 to 18.0Motor Mounting 105021 2-56 2.5 to 3.5Cover PCB Mounting 105021 2-56 2.5 to 3.5Dial Ring PCB Mounting 105030 6-32 9.0 to 11.0Lock Case Cover 105030 6-32 9.0 to 11.0Dial Ring Mounting 105034/105158 8-32 17.0 to 20.0Dial Ring Cover 105034 8-32 17.0 to 20.0Spindle 105219 5-40 14.0 to 16.0Lock Case Mounting 105046/105195 1/4-20 25.0 to 30.0Dial Hub Set Screw 105057 8-32 17.0 to 20.0Tube Retainer (D.R.) Mounting 105059 4-40 4.0 to 5.0

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LOCK PARTS FOR INSTALLATION

1. Lock assembly2. Dial ring assembly3. Dial assembly4. Dial hub assembly

INSTALLATION KIT CONTENTS

1. Lock assembly attachingscrews (4)

2. Dial ring assembly attachingscrews (2)

3. Tube, inner4. Tube, outer5. Blade, saw (52 teeth/inch)6. Handle, saw7. Stone, tube deburr8. Gage, tube cut-off9. Gage, dial hub locating10.Hexkey (5/64”)11. Lubricant12.Rubber vise clamp

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TEMPLATEA template is provided as an aid for locating, drilling, and tapping the lock caseand dial ring mounting screw holes relative to the spindle hole. Since the lockis designed to fit most industry standard container lock mounting screw holepatterns, 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 withthe lock for installation purposes.

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PREPARATION FOR NEW INSTALLATION OF THE LOCK1. Use the template to establish the exact relative locations of all of the

necessary mounting holes for the lock case and the dial ring, whennecessary.

2. The lock case mounting screws require drilled and tapped 1/4-20 screwholes.

3. The dial ring mounting screws require drilled and tapped #8-32 screwholes.

4. The spindle hole must be 0.375 inch diameter, minimum.

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INSTALLATIONINSTALLATION OF THE LOCK

1. Remove the two screws from thelock assembly cover and removethe cover.

2. Remove the drive cam/spindleassembly from the lock caseassembly.

Note: It is possible to order somelocks from the factory with pre-cuttubes and spindle. If you have alock installation with pre-cut parts,you may skip to “Installation of thedial ring”.

3. Feed the cables through the outer (larger) tube.4. Seat the tube into position on the tube retainer on the back of the lock case

assembly. (See Figure 1) Be careful to keep the cables pulled taut whileseating the tube to avoid pinching damage to them.

Figure 1 Tube-Cable Assembly Relationships

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5. 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 easilyaccessible at the outside wall of the container. On some containers, theonly way to do this is to retract the bolt. If this is the case, remember toextend the bolt and slide to their fullest extension after installing the lockcase mounting screws and before continuing.

Note: Another outer tube inserted from the dial ring side would be veryhelpful as a guide for greater ease in feeding the cables through thecontainer wall.

6. Attach the lock case assemblyto the container wall using thelock case mounting screws.

7. While holding the outer tubeagainst its seat on the tuberetainer, move the lock caseassembly around until the tubeis reasonably centered in thehole in the outside containerwall.

8. Tighten the lock case mountingscrews to hold the lock casefirmly in place.

INSTALLATION OF THE DIAL RING1. Remove the two screws from

the dial ring assembly coverand remove the cover.

2. Remove the two screws fromthe cable/tube retainer andremove it.

3. Work the ZIF seal out of itsholder and remove the LCDfrom the dial ring.

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4. Remove the 4 screws from thetube retainer and remove thetube retainer and the ZIF sealholder.

Note: With pre-cut tubes thisstep is not necessary. In thiscase, the dial ring can bemounted with the tube retaineralready in place.

5. Guide the cables and the outertube through the center hole ofthe dial ring, so that they are botheasily accessible inside the dialring.

6. Set the dial ring assembly inplace against the outsidecontainer wall while entering thetube in the center hole of the dialring. Insert and tighten the twomounting screws.

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INSTALLATION OF THE OUTER (LARGER) AND INNER(SMALLER) TUBES AND SPINDLE

Note: If you have a lock installation with pre-cut parts, you may skip tostep 9.

1. Place the tube cut-off gageover the end of the outer tubeand against the inside wall ofthe dial ring.

2. Make sure that the outer tubeis properly seated on the lockcase tube retainer.

3. While holding the outer tubefirmly in its seated positionand with the tube cut-off gagepressed against the dial ringwall, mark the tube for cutting.

4. Remove the lock caseassembly from the containerand remove the outer tube forcutting.

5. Assemble the saw blade in tothe wooden saw handleprovided. When the saw frameneck is fully seated into thehandle, grip the saw frame(preferably in a vise) and tap thehandle another 1/8” to 1/4” ontothe saw frame neck. This willreduce the tendency of thehandle to turn on the saw framewhen sawing.

Note: This saw is intended to beused only to cut the tubes. Astandard hacksaw should beused to cut the spindle.

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6. Insert the tube to be cut into therubber vise clamp (provided).Then firmly clamp the rubbervise clamp in a vise. Use thesaw to cut the tube wheremarked. Be careful to keep thecut as straight as possible.Remember the saw only cutswhen pushing. Trying to cutwhile pulling may pull thehandle off the saw blade.

Warning: The end of the largetube that is to be discarded mustbe from the plain (unflared) endof the tube. The end of the smalltube that is to be discarded mustbe from the plain (unnotched)end of the tube.

7. Use the piece cut from the outertube to measure and mark theinner (smaller) tube. The sameamount will be cut from eachtube. The rubber vise clampshould also be used whilecutting.

8. The inside of the tubes mustbe deburred after cutting. Usethe stone which is provided forthis purpose.

9. Place the inner tube (smaller)into the lock case tube retainer.Make sure that the cutout in thetube aligns with the cables andallows the inner tube to seatcompletely in the tube retainer.

10.Feed the cables through theouter tube while placing theouter tube over the inner tube.Seat the outer tube completely onto the tube retainer. (See Figure 1.) Becareful to keep the cables pulled taut while seating the outer tube to avoidpinching damage to them.

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11. Carefully guide the tubes andcables through the walls of thecontainer, making sure that thetubes remain properly seated onthe tube retainer. (See Installationof the Lock step #5.) Position thelock case assembly against theinner wall of the container. Insertand tighten the mounting screwsto hold the lock case assemblyfirmly in place.

Note: Placing the outer tube into position in the container wall first andfeeding the cables and the inner tube through it, will make assemblyeasier on the thicker walled containers.

12.Place the tube retainer spring intothe dial ring with its raised centerportion facing outward. Feed thecables through its center hole andposition it over the tubes so thesmall tube slides through itscenter hole and it rests againstthe end of the larger tube.

Caution: Do not turn the retaineronce it is placed over the tubes.

13. Insert the upper left screw.

14. Place the ZIF seal holder in thelower right quadrant of the dial ringwith its tab positioned under thetube retainer spring. Insert a screwthrough both parts and start it intothe hole.

15.Rotate the seal holder clockwiseto assure approximately 1/8 inchclearance between it and the dialring at the bottom. Tighten thescrew.

16. Insert the other two screws andtighten them all.

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17.Open the ZIF (Zero InsertionForce) seal cover and movethe ZIF connector lockingactuators outward to their openposition. (See Figure 2.)

Figure 2 Plugging Cables Into the ZIF Connector

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18.Plug the cables into the ZIFconnectors. The bright metaltabs on the cables should befacing toward the circuit boardto which the ZIF connectorsare attached.

19.The 5-conductor cable goesinto the ZIF connector nearestthe cable connecting to theLCD. The 4-conductor cablegoes into the ZIF connectoraway from the cableconnecting to the LCD. Closethe ZIF locking actuators tolock the cables in place.

Note: The 3/16 inch long darkened section of the cable under thebright metal tabs should be completely inside the ZIF connector whenproperly installed.

20.Place the LCD into the dial ring. Note that the cable coming out of the LCDis nearer one edge than the other. The side nearest the cable should faceoutward, away from the dial ring, when installed.

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21.Close the ZIF seal. Rotate theseal into the seal holder soits beveled side with thecable clearance slots isfacing outward and towardthe center of the dial ring. Thecables must exit the top of theseal and lay in the clearanceslots going toward the centerof the dial ring.

22.Replace the cable/tuberetainer, being careful toposition the cablesunderneath so that they willnot be pinched or damagedin any way. Insert and tightenthe (2) screws.

23. Install the dial ring cover andtighten the cover screws.

24. Install the drive cam/spindleassembly into the lock caseassembly until the drive camis properly seated and thespindle extends through thedial ring cover.

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Note: To avoid unnecessarydamage - always make surethat the motor gear is in itsproper detent position wheninserting the drive cam/spindleassembly. If it is not, a pencilmay be used to move it to theproper position.

Correct Gear Position

Incorrect Gear Position

Incorrect Gear Position

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25.Check the spindle for freedomto rotate without scraping. Ifscraping does occur, loosenthe dial ring mounting screwsand center the dial ring aroundthe spindle until the scrapingis eliminated. It may also benecessary to adjust thepositioning of the lock caseassembly.

26.Place the dial hub assemblyonto the spindle. Push the dialhub tightly against the dial ringcover while pulling on the spindle and lightly tighten one set screw againstthe spindle.

27. Using a hacksaw,cut the spindle flush with the dial hub assembly. Filespindle if necessary to remove burrs and insure proper fit in dial.

Caution: Do not lubricate the lock except as directed by theseinstallation instructions. Proper lubrication of the lock has beenperformed at the factory.

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INSTALLATION OF THE DIAL HUB AND DIAL

1. Loosen the set screw andremove the hub.

2. Apply lubricant to the hubbearing surface.

3. While holding the drive cam in itsproper position in the lock caseassembly inside the container,push the dial hub assembly ontothe spindle.

4. Place the dial hub locating gaugeover the spindle and between thedial hub assembly and the bushingin the dial ring cover. This sets upan initial .010” end play.

Recommendation: Make a bend inthe dial hub locating gauge at itsmidpoint. This will keep it from actingas a spring as the hub is positionedfor locking to the spindle.

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5. While maintaining a constant pres-sure on the dial hub and the drivecam assemblies, pushing themtoward each other, SECURELYtighten the set screws in the dialhub assembly to 17- 20 inches/pound of torque ( a minimum of 1”deflection of the handle of thehexkey). Remove the dial hub locat-ing gauge.

Caution: Tighten in a downwardmotion in case the hexkeyshould break.

6. Apply lubricant generously to theretaining ring on the dial hubassembly and position theretaining ring so that an equalamount of it is consistentlyexposed around the hub. Also,apply grease from the lubricanttube to the entire ramp area justinside the back of the dial.

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Note: Make sure the ends of theretaining ring bracket the set screwsin the hub and that an equal amountof the retaining ring is exposed aroundthe hub so the dial can slide easilyinto place on the hub withoutinterference from the retaining ring.

7. Carefully place the dial over the dialhub assembly and apply pressureto the dial until the retaining ringseats in the dial.

Note: You should not be able to pullthe dial away from the dial hubassembly.

8. Replace the lock case coverassembly. Insert and tighten the (2)cover screws.

INSTALLATION COMPLETION CHECKLIST1. Does the dial turn freely without scraping or binding?2. Have all screws been securely tightened?3. Dial the combination (it has been factory set to 50-LEFT, 25-RIGHT, 50-

LEFT). Your Model X-07 should turn freely without scraping or rubbing andshould open when the correct combination has been dialed. (See GeneralInformation: Dialing Instructions-Single Combination Mode). If the lock isa CEX-07, it will display CE when it is powered up and will not operateuntil the combination is reset. Use the following procedure to reset thecombination.

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RESETTING COVERT ENTRY AND COVERT ENTRYCOMBINATION CHANGE

This procedure works only if the lock is powered down when dialing to the right(CW), with the change key out of the lock.Dialing to the right (CW) on lock startup will display the open counter. Once theopen counter is displayed, insert the change key. If there is a covert entry or thechange key is in, continuing to dial to the right will result in dialing an ID. The IDis selected when the direction is reversed. The lock level is not displayed whenthe change key has been inserted, or there has been a covert entry. Instead, thenumbers for selecting an ID are displayed.Dial to 99 and reverse directions, After reversing directions, dial the covert entrycombo starting to the left as with the other combinations. If the combination iscorrect, the covert entry condition will be reset.The default covert entry combination is 50 25 50.To change the covert entry combination, dial to the right until the open counter isdisplayed. The change key needs to be inserted during the open counter dis-play. If it is in before the open counter display it will not be recognized. Begin bydialing right to ID 99 and then dialing the current covert entry combination. If thecombination is correct, you will be able to enter and confirm the new covert entrycombo the same as changing a single normal combination. The lock will openupon completing the combination change.

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Document Number 001.123 Rev. D 11/98Converted to Acrobat 08/00

Notice: The information in this manual is subject to change without noticeand does not represent a commitment on the part of Mas-HamiltonGroup (MHG). MHG shall not be liable for technical errors or omis-sions contained herein; not for incidental or consequential damagesresulting from the furnishing, performance or use of this material.

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