DELUXE HIGH SECURITY SET LKM116 INSTRUCTIONS

DELUXE HIGH SECURITY SET LKM116 INSTRUCTIONS S&G 8400/8500 DRILL GUIDE LKM115 INSTRUCTIONS

X-O7 Dial Puller & Drill Guide Components X-O7 DIAL SPACER RING Puller cup cup handle Spindle bolt Puller bolt Spindle Knob 8400/8500 drill guide Fence drilling jig & drill 3/32, 3/16, 9/64 & 5/32 Allen wrenches X-lock drill guide The X-Lock Dial Puller & Drill Guide is a unique set of tools that have been designed to aid the safe technician in neutralizing a lock out on the Mas-Hamilton/Kaba Mas X- Lock Series. Although the X-Lock Dial Puller & Drill Guide is simple to use, it will nevertheless be wise for all new owners and users to read this book with care. Keep in min as you read, and as you begin to use the X-Lock Dial Puller & Drill Guide that it is, in a sense, a hand tool. Like any other hand tool, continued use and practive will increase the operator s skill. Power tools will be required in the use of the X-Lock Dial Puller & Drill Guide. General Safety Instructions for Power Tools Know Your Power Tool Read and understand the owner s manual and labels affixed to the tool. Ground All Tools Ensure your tools has an approved 3 conductor cord and a 3 prong grounding type plug to fit the proper grounding type receptacle. Keep Work Area Clean Cluttered areas and benches invite accidents. Floor must not be slippery due to waxes or other liquids. Keep Children Away All visitors should be kept a safe distance from your work area. X-O7 Dial Puller instructions Step 1 - Insert the X-O7 dialspacer ring inside the puller cup handle and align the 3-pointed hex sctews with the X-O7 dial spacer ring. Thread the three screws into tthe spacer to hold it in place. Follow steps 2-8 to remove dial. Note: The spacer ring is only used when pulling the dial on an X-O7 lock.

Step 2 - Place the Puller Cup over the nose of the dial, which will self-center over the spindle. Use the provided 3/16 Allen wrench and firmly tighten the 3-pointed Hex head screws. Tighten pointed Hex head screws until the start biting into the nose of the dial. Step 3 - Thread the Cup Handle onto the Puller Cup and hand tighten. Step 4 - Thread the Spindle Bolt into the center of the Puller Cup until it stops. The guide hole in the center of the Spindle Bolt will accommodate a 1/4 high-speed drill bit. The dial is aluminum and zinc alloy so it is very soft. The best approach to drilling is a sharp drill bit, low RPM and moderate pressure. Hold your drill in one hand and the Cup Handle in the other to insure the dial does not spin as the drill is turning. Step 5 - There are two hardened set screws that hold the dial onto the spindle, this will be the stopping point. The depth from the face of the dial nose to the first set screw is 7/32. Using the Spindle Bolt as a guide, drill into the Dial Nose until you feel a vibration, this is the drill bit making contact with the first hardened set-screw. Stop drilling at this point. Step 6 - Remove the Spindle Bolt from the Puller Cup and replace it with the Puller Bolt. The Puller Bolt has an extension rod that will make contact with the dial spindle. Using a adjustable wrench or a 15/16 box end wrench and holding firmly onto the Cup Handle, start threading the Puller Bolt clockwise into the Puller Cup. The dial will start separating from the spindle.

Step 7 - The distance required to completely remove the dial is approximately 3/8 from the bottom of your drilled hole or 9/16 from the face of the Puller Cup. When the dial has been removed, the Puller Cup can be separated from the dial by loosening the 3-set screws. Remove the Spindle Bolt from the Puller Cup and set aside. Step 8 - The Spindle Knob provides turning torque needed to retract the bolt after the hole has been drilled. The Spindle Knob attaches to the Spindle with a set-screw. Use the 3/32 Allen wrench to tighten the Spindle Knob to the Spindle. X-07 Dial Replacement Parts Note: Replacement parts for the X-07 are no longer available. X-08 Dial Replacement Parts Note: Replacement parts for the X-08 are no longer available. X-09 Dial Replacement Parts MAS504068 X-09 Snap-on Dial MAS501226 X-09 Hub Assembly MAS504069 X-09 Spindle 4.5 MAS104017 Tube Kit 4.5

THe X-LOCK DRILL GUIDE Operation The X-Lock drill guide has four drill points mapped out. Hole P targets the pin on the X-O7 lever. This will usually be the primary drill point because the pin is located well inside the diameter of the dial ring, making repair much easier. Hole L targets the X-O7 lever screw which is usually the secondary drill point since this hole is located near the perimeter of the dial ring making repair a little more difficult. Hole L targets the internal relock device on all X-Locks. Hole M targets the motor gear on the X-O8 and X-O9 lock, which is the primary drill point for these locks With the dial ring removed attach the drill guide to the container using the 8-32x5/8 cap screws provided. Notice the eight mounting holes. The four inner most holes are for installation on a Mosler container, the four outer most holes are for Hamilton, Overly HHM, etc. The layout of the attaching screws will allow the drill guide to be mounted in four different positions depending on the handling of the lock, vertical up (VU) vertical down (VD) right hand (RH) left hand (LH). The drill guide is marked with an arrow and Bolt Side stamped on it. Spindle Knob The Spindle Knob attaches to the spindle with a set screw. Use the 3/32 Allen wrench provided to tighten the set screw to the spindle. The Spindle Knob provides the turning torque needed to dial the lock and to retract the bolt.

8400/8500 Drill Guide The 8400/8500 Drill Guide is a unique drilling template that has been designed to target the fence, relock and lever screw on Sargent & Greenleaf 8400 and 8500 Series Group I Combination Locks with the Spy-Proof dial and dial rings. The 8400/8500 Drill Guide attaches directly to the dial ring with 4 hex head cap screws. There are 2 additional hex head cap screws that will stabilize the dial. There is no need for dial or dial ring removal. The 8400/8500 Drill Guide is designed to target the fence, relock and lever screw in any of the 4 mounting positions of the lock. There is no technical expertise needed to lay out drill points. lthough the 8400/8500 Drill Guide and Fence Drilling Jig are simple to use, it will neverthelesss be wise for all new owners and users to read this book with care. Keep in mind as you read, and as you begin to use the 8400/8500 Drill Guide and Fence Drilling Jig that it is, in a sense, a hand tool. Like any other hand tool, continued use and practice will increase the operator s skill. Power tools will be required in the use of the 8400/8500 Drill Guide and Fence Drilling Jig. 8400/8500 Drill Guide Operation Index Pin Index MARK The 8400/8500 Drill Guide has been specifically designed to fit over the Spy-Proof dial and dial ring of the Sargent & Greenleaf 8400 or 8500 Series locks. There are 2 index pins that will align the 8400/8500 Drill Guide to the Spy-Proof dial and dial ring. Once the 8400/8500 Drill Guide is in place, tighten the 4 hex head cap screws at 20, 40, 60 and 80 to the dial ring with the 3/16 Allen wrench provided. Then tighten the 2 hex head cap screws at 90 and 10 to the dial. There are 2 purposes for these last 2 hex head cap screws. First, to stabilize the dial at 0, the position at which the lever will drop, and secondly, to provide more holding power for the 8400/8500 Drill Guide. The drill guide is made in 2 pieces. The outer cup, which remains stationary when secured, and the inner template which can be rotated to compensate for the hand of the combination lock. The drill guide in the diagram is set up to drill a right hand mounted lock. When it is necessary to change the handing of the drill guide, remove the 2 cap screws located on the front of the drill guide. Rotate the inner template for the desired lock handing to the index mark located on the right hand side of the outer cup. Once the inner template has been positioned, replace the 2 cap screws in the front. There are 3 drill points mapped out on the drill guide. Hole A will be the primary target which is the location of the fence. Hole B will usually be the secondary target and is the location of the lever screw. Drilling for the lever screw is more difficult since you have little margin for error. Hole C is used to neutralize the internal spring-loaded relock. It is suggested that your finish hole be 5/16 in diameter. This will allow for extra room to maneuver within the drilled hole in order to neutralize the fence or the lever scrw. The use of this tool requires a 6 drill bit. L H V U V D R H

Tips for Drilling the Fence All you have to be is close. Close enough that is to bend the fence towards the center of the drilled hole. With this accomplished, there are a couple of ways to eliminate the fence. You could try drilling it off freehand, use a hole saw to remove that portion of the lever holding the fence or use the Fence Drilling Jig provided with the 8400/8500 Drill Guide. The Fence Drilling Jig has 2 parts, the tube with knurled brass handle and 6 extension drill and the 2 parts together. Index MARK The Fence Drilling Jig is designed to aid the safe technician in removing the fence on combination locks whose fence is coming towards you as it is on some Sargent & Greenleaf, LaGard and Ilco locks. The drilled hole size cannot be less than 1/4 and the depth from the face of the safe to the lever shoudl not exceed 3-1/2. It is not ciritical for the drilled hole to be centered on the fence. If your drilled hole is off center, use an ice pick or similar tool to bend the fence towards the center of the drilled hole. To use, insert the drill into your hand held drill motor. Insert the tube into the drilled hole of the safe. While twisting the tube back and forth, slide the tube onto the fence allowing it to bottom out on the lever. Hold the tube firmly, insert the drill into the tube, turn on the drill motor and carefully drill away the fence. The depth required to completely remove the fence from the lever is 5/8 for a 3 wheel lock. For a 4 wheel lock, the depth required is 3/4. B L H V U V D C A R H A-Fence B-Lever Screw C-Relock