DOM Sigma Plus Assembly Instructions Manual

YOUR SAFETY .......................................................................................................... 4 Important Notes........................................................................................................ 4 SCOPE OF DELIVERY .............................................................................................. 5 PREPARATION.......................................................................................................... 6 Tools ........................................................................................................................ 6 Service box .............................................................................................................. 7 ASSEMBLY................................................................................................................ 8 Preparation of assembly superstructure................................................................... 9 Filling of cylinder body............................................................................................ 13 Filling of cylinder core............................................................................................. 21 Insertion of the cylinder core into cylinder body ..................................................... 24 Type 333 ................................................................................................................ 25 Type 333H.............................................................................................................. 27 Type 333T .............................................................................................................. 29 Type 333K.............................................................................................................. 31 Type 333KL............................................................................................................ 34 Type 382 ................................................................................................................ 37 Type 555 ................................................................................................................ 39 Type 777 ................................................................................................................ 41 MAINTENANCE ....................................................................................................... 43 STORAGE/MAINTENANCE..................................................................................... 43 DISPOSAL ............................................................................................................... 43 TECHNICAL DATA SIGMA PLUS........................................................................... 44

combinations can be obtained with the 6 sprung locking element pairs. You can use one key to open everything – from front door to briefcase, from garage door to window handles. You can also subsequently obtain additional cylinders for your new Sigma Plus system, which you can open with your Sigma Plus key. If required, we can also offer the Sigma Plus system in a modular design, to provide an additional increase in the break-off values and length flexibility. DOM Sigma Plus is perfectly suited for the use in (general) master key systems or central lock (master key) systems.

4 Your Safety Always comply with the instructions and security statements! In this assembly instructions, several sections are marked by graphical symbols. Please memorise the graphical symbols and their meanings: Caution! This symbol marks a danger note and/or refers to an action that may cause damage to the mechanical cylinder or other objects. Note! This symbol refers to useful information on assembly or operation. Important Notes Caution! Keep the mechanical cylinder and its components away from small children. They might swallow small parts. Caution! Material damage caused through incorrect storage. If you store mechanical cylinders for a longer period of time before assembly, store all components dry and dust-free in the original packaging. Caution! Damage caused through inexpert assembly. Please read these instructions completely and carefully before assembly. Follow the instruc- tions step by step. The manufacturer accepts no liability for damage re- sulting from an inexpert assembly. Caution! Defects caused by untrained personnel! Only extensively trained personnel are allowed to assemble DOM cylinders. The manufac- turer disclaims liability for any defects caused by untrained personnel.

5 Scope of delivery For each Sigma Plus contract you will receive the following documents: 1. Service card / Identification card 2. Client worksheet 3. Encoded worksheet 4. Table of assembly superstructure of the cylinder 5. Supplementary sheet for high-level keys To fabricate spare cylinder and spare keys please use the coded worksheet, tables of assembly superstructure of the cylinder and supplementary sheet for high-level keys. The principal of the locking system will receive service card and client’s worksheet. Note! The principal of the locking system shall assure safe storage of the service card at a place where only authorized persons have access to.

proper core and body pins and the proper tools. Caution! Damage caused through inexpert assembly. Please read these instructions completely and carefully before assembly. Follow the instruc- tions step by step. The manufacturer accepts no liability for damage re- sulting from an inexpert assembly. Caution! Defects caused by untrained personnel! Only extensively trained personnel are allowed to assemble DOM cylinders. The manufac- turer disclaims liability for any defects caused by untrained personnel. Tools Caution! Defects caused by applying improper tools! The tool DOM Sicherheitstechnik provides for cylinder assembly is tuned to all requirements of professional assembly. The manufacturer disclaims liability for any damages or defective assembly caused by the application of other tools. You need the following tools: 1 2 3 4 5 7 8 6 Fig. 1: Tools 1: assembly clam (400269) 2: loading knife (261674) 3: follower (266009) 4: assembly clam for type 382 (405634) 5: pliers for cam type KL (265776) 6: Assembly bushing (266674) 7: pliers for extension piece (261669) 8: pliers for cam (263629)

7 Service box DOM Sicherheitstechnik has compiled an service box for system Sigma Plus that contains all necessary sorts of pins (body pins, core pins) as well as masterkey wa- fers. You may order this service box directly via DOM Sicherheitstechnik. Thus you are always well equipped with all tools and necessary pins. Note! This service box also exists for other systems, e.g. for ix 6 KG, Diamant, etc.. Core pins N N N N No. 0 No. 1 No. 2 No. 3 4,85 mm 5,25 mm 5,65 mm 6,05 mm 509254 112 509255 112 509256 112 509257 112 AB AB AB AB No. 4 No. 5 No. 6 No. 7 6,45 mm 6,85 mm 7,25 mm 7,65 mm 509259 112 509260 112 509261 112 509262 112 Cam End piece Cam Cam Coupling Coupling half half standard double entry standard double entry new design 218426 008 204217 218228 008 235855 008 502154 235860 Body pins N N FB FB No. 0, 1, 2, 3 No. 4, 5, 6, 7 No. 0, 1, 2, 3 No. 4, 5, 6, 7 5,5 mm 4,5 mm 5,5 mm 4,5 mm 509264 112 509265 112 509268 112 509269 112 H H H H No. 0, 1 No. 2, 3 No. 4, 5 No. 6, 7 5,6 mm 4,6 mm 3,6 mm 3,1 mm 509271 509272 509273 509274 Masterkey Masterkey Masterkey Profile pin Spring Spring Security ring wafers wafers wafers RD 2,7 x 14 V2A 0,8 mm 1,6 mm 2,4 mm V2A 382, 393 1,0 mm 509250 509251 509252 509276 333, 555, 777 243515 202335F 242172 The box contains single compartments where you can sort in pins. The following fig- ure shows how the wrapped pins are sorted in the service box ex works. Note! A list of contents is part of the service box. You may make use of the sequence of pins according to the list of contents to avoid confusion. Note! The assembly tools may be delivered together with the service box on your explicit order.

Caution! For assembly please use only the special tool that is described in the assembly steps. Manufacturer disclaims liability for any defects caused by application of inappropriate tools. Note! Please use a soft pad for assembly, such as a foam rubber. Thus you ensure that no pins drop out of the cylinder core when placing the core into the body. Note! All material numbers for common spare parts are specified to- gether with the respective step of assembly. At first all common steps of assembly that apply for all types of cylinders will be de- scribed in the assembly instructions. So at first basic handling of the assembly su- perstructure, body filling, core filling and core fitting into body are specified. Subse- quently each step of assembly will be described. These apply for the respective type of cylinder only.

9 Preparation of assembly superstructure For each Sigma Plus contract you receive a sheet with tables of assembly super- structures of the cylinders. If positions of core and body pins are not stated in the ta- ble ex works please enter the pins in the table. The following shall apply: The FB body pins may only be assembled at the first five positions, maximally 2 at each side of the cylinder. FB body pins are assemble to the positions with the lowest values. In case of su- perstructures (master key system), the lowest value including the superstructure is considered. Only N pins are available as core pins for the lengths of 0, 1, 2, 3, and for the lengths 4, 5, 6, 7 only AB pins are available. There is no restriction of the positions for core pins. The core pins are applied at positions P1 – P6 depending on their lengths. Assembly without masterkey wafers Body pins 4 5 1 2 3 5 FB FB P1 P2 P3 P4 P5 P6 4 5 1 2 3 5 N N FB FB N N P1 P2 P3 P4 P5 P6 1.) At first the two FB-body pins are inserted at the positions P1 – P5 with the lowest val- ues. (here: position P3=value 1 and P4=value 2) 2.) N-pins are inserted at the remaining posi- tions.

10 Assembly with masterkey wafers Body pins 4 5 1 2 3 5 3 4 5 6 7 P1 P2 P3 P4 P5 P6 4 5 1 2 3 5 3 4 5 6 7 FB N FB N N N P1 P2 P3 P4 P5 P6 4 5 1 2 3 5 3 4 5 6 7 FB N FB N N N P1 P2 P3 P4 P5 P6 For assembly superstructures with masterkey wafers the highest plate structure determines the body pin as stated in the lower cells of the re- spective columns. 1.) At first the two FB-body pins are inserted at the positions P1 – P5 with the lowest val- ues in the lowest cells. (here: position P1=value 4 and P3=value 3) 2.) N-pins are inserted at the remaining posi- tions P2, P4, P5 and P6.

11 Assembly without masterkey wafers Note! Only N pins are available as core pins for the lengths of 0, 1, 2, 3, and for the lengths 4, 5, 6, 7 only AB pins are available. Core pins AB AB N N N AB 4 5 1 2 3 5 P1 P2 P3 P4 P5 P6 The core pins are applied at positions P1 – P6 depending on their lengths. here: Position P1, P2 and P6: AB-pin; Position P3, P4 and P5: N-pin Assembly with masterkey wafers Core pins AB AB N N N AB 4 5 1 2 3 5 3 4 5 6 7 P1 P2 P3 P4 P5 P6 For assembly superstructures with masterkey wafers the values of core pins are shown in the upper cells. Assignment of pins is done similar to assembly superstructures without masterkey wafers. (see above)

core N AB N N N AB 0 4 1 2 2 6 FB N FB N N N P1 P2 P3 P4 P5 P6 body There is no restriction of the positions for core pins. Therefore, an AB pin is applied at position P6 depending on length. Sample lockings with masterkey wafers core N AB AB AB AB N 3 4 7 5 6 3 5 FB FB N N N N P1 P2 P3 P4 P5 P6 body If two values of the body pins are equal (here: length 5 on pos. P1 and P4), the FB body pin must be inserted at the first possible position. (here at pos. P1)

13 Filling of cylinder body Note! Depending on the length of the locking sides, two different core lengths are applied: core 0 (509425) and core 5 (509426). Compared with core 0, core 5 is 5 mm longer. In case of a cylinder which deviates from the standard sizes, you must insert a core extension piece with cyl- inder pin, if necessary. Double cylinder (standard) A B A B A B 30 30 0 0 --- --- 35 30 5 0 --- --- 40 30 0 0 203643 --- 45 30 0 0 203644 --- 50 30 0 0 203645E --- 55 30 0 0 203643+44 --- 60 30 0 0 203643+45E --- 65 30 0 0 203644+45E --- 70 30 0 0 203647E --- 35 35 5 5 --- --- 40 35 0 5 203643 --- 45 35 0 5 203644 --- 50 35 0 5 203645E --- 55 35 0 5 203643+44 --- 60 35 0 5 203643+45E --- 65 35 0 5 203644+45E --- 40 40 0 0 203643 203643 45 40 0 0 203644 203643 50 40 0 0 203645E 203643 55 40 0 0 203643+44 203643 60 40 0 0 203643+45E 203643 45 45 0 0 203644 203644 50 45 0 0 203645E 203644 55 45 0 0 203643+44 203644 50 50 0 0 203645E 203645E 211590 211590 211590 211589 211591 211589 211592 211588 211589 211589 211590 211588 211591 211588 211593 211587 211588 211589 211588 211590 211587 211587 211592 211587 211587 211587 211587 211589 211587 Cylinder pin standard A B --- --- 211587 --- 211588 211589 211590 211593 211588 211591 211588 Lock side Core (mm) Core extention 211591 211592 --- --- --- --- --- --- 211594 ---

14 Double cylinder (double entry) A B A B A B 30 30 0 0 --- --- 35 30 5 0 --- --- 40 30 0 0 203643 --- 45 30 0 0 203644 --- 50 30 0 0 203645E --- 55 30 0 0 203643+44 --- 60 30 0 0 203643+45E --- 65 30 0 0 203644+45E --- 70 30 0 0 203647E --- 35 35 5 5 --- --- 40 35 0 5 203643 --- 45 35 0 5 203644 --- 50 35 0 5 203645E --- 55 35 0 5 203643+44 --- 60 35 0 5 203643+45E --- 65 35 0 5 203644+45E --- 40 40 0 0 203643 203643 45 40 0 0 203644 203643 50 40 0 0 203645E 203643 55 40 0 0 203643+44 203643 60 40 0 0 203643+45E 203643 45 45 0 0 203644 203644 50 45 0 0 203645E 203644 55 45 0 0 203643+44 203644 50 50 0 0 203645E 203645E Halve cylinder 511242 + 249759 511242 + 249759 511242 + 249759 511242 + 246291 511243 511243 511243 511243 511242 511242 511242 511243 511242 511242 511242 511242 511242 + 246291 --- --- --- --- --- --- --- --- --- 511242 + 246293 511242 + 249759 511242 + 246291 511242 + 246292 511243 511242 + 249759 511242 + 246291 511242 + 246292 511242 + 246291 511242 + 246292 511242 + 246293 511242 + 246294 511242 + 246295 511242 511243 511242 + 249759 511242 + 246291 511242 + 246292 511242 + 246293 511242 + 246294 --- 511242 511243 511242 + 249759 A B Cylinder pin double entry 50 0 203645E 45 0 203644 40 0 203643 35 5 --- 30 0 --- Length Core Core extention (mm) (mm) Lock side Core Core extention

15 Fig. 2: Insert extension piece 1. If necessary please insert a core extension piece with the appropriate cylinder pin. Note! Please hold the table of assembly superstructure ready. The body pins are always stated in the last cell of a column. The following table of assembly superstructure shows the body pins highlighted in grey. Body pins 0 3 1 4 1 6 2 5 4 5 6 Example N N FB FB N N P1 P2 P3 P4 P5 P6 Type 382 H H H H H H Body pin N: 0 – 3: 509264 112 = 5,5 mm 4 – 7: 509265 112 = 4,5 mm Body pin FB: 0 – 3: 509268 112 = 5,5 mm 4 – 7: 509269 112 = 4,5 mm Body pin H: 0: 509271 = 5,6 mm 1: 509271 = 5,6 mm 2: 509272 = 4,6 mm 3: 509272 = 4,6 mm 4: 509273 = 4,1 mm 5: 509273 = 4,1 mm 6: 509274 = 3,1 mm 7: 509274 = 3,1 mm Note! When using hollow body pins (type 382) the corresponding N and FB-body pins are inapplicable.

16 Caution! Position and number of pin types are prescribed: FB-body pins: On each lock side two FB-body pins are inserted. FB- pins may only be assembled at positions P1 – P5. The FB-body pins have to be inserted on the positions with the lowest values (here P3 and P4). N-body pin: On each lock side at least four N-body pins are inserted. Note! The pins mentioned in the table, read from left to right, have to be inserted on the follower from inside to outside. inside 6 N 5 N 1 FB 4 FB 5 N N 6 outside Fig. 3: Cylinder assembly superstructure body pins 2. Please select the necessary body pins. Fig. 4: Filling of follower 3. Please insert the body pins into follower correspondingly to the de- fined position. 4. Please apply compression springs (242172) on the pins. 5. Using the loading knife, insert the springs into the follower to such an extent until the knife provides flush fit with the follower.

17 Caution! Material defects caused by improper insertion of the follower! If the follower is inserted too far/not far enough into the cylinder body the compression springs might be damaged. Note! When mounting type KL you must assemble the long side,first. Fig. 5: Insert follower together with loading knife into the cylinder body 6. Please insert the follower incl. loading knife carefully into the cyl- inder body to such an extent until the front edge of the follower pro- vides approx. flush fit with the in- ternal body edge (base length 30 mm) or the retainer ring device (ex- tended version). Springs and pins overlap the boring in the cylinder body a little. 180° Fig. 6: Turning follower together with load- ing knife 7. Please turn follower incl. knife to such an extent until the mounting is positioned over the borings in the cylinder body.

18 Fig. 7: Pulling out loading knife 8. Please pull out the loading knife. 9. Please turn follower carefully back and forth until body pins are in- serted into the respective core bor- ings. Fig. 8: Reinsertion of loading knife above the pins 10. Please reinsert loading knife care- fully above the pins.

19 Fig. 9: Fixing of springs and pins in the cylinder body 11. Please press the pins carefully against the spring force into the cylinder body until the follower may be turned. 12. Please turn follower to such an extent until the big groove is posi- tioned over the borings in the cyl- inder body. Fig. 10: Pull out loading knife 13. Please remove loading knife. Note! If you install type KL (initially the longer side without assembly bracket) or type 555 (without assembly bracket), you must leave the as- sembly bar in the cylinder body and go to page 21 and first fill the cylin- der core. If you assemble type 382 make sure you insert assembly clam from be- hind.

20 Fig. 11: Insert assembly clam 14. Please insert assembly clam accu- rately fitting. Fig. 12: Pulling out follower 15. Please remove the follower without pulling out the assembly clam. Now the pins and springs are fixed within the cylinder body. 16. Before continuing the assembly please check whether all springs and pins from the follower are fixed in the body.

21 Filling of cylinder core Note! The filling of cylinder core should be done on a soft pad, e.g. foam rubber, in which you may press the core gently. Using a soft pad may help you to insert the core into the body without problems. Thus the pins do not fall out again. For assembling a cylinder with freewheel the core 511256 is needed. Core pins Note! In the table of assembly superstructure you will find the core pins in the upper row. Core pins N N N AB N AB 0 3 1 4 1 6 2 5 4 5 6 P1 P2 P3 P4 P5 P6 Core pin N: 0: 509254 112= 4,85 mm 1: 509255 112= 5,25 mm 2: 509256 112= 5,65 mm 3: 509257 112= 6,05 mm Core pin AB 4: 509259 112 = 6,45 mm 5: 509260 112 = 6,85 mm 6: 509261 112 = 7,25 mm 7: 509262 112 = 7,65 mm N N N ABN AB Fig. 13: Numbering of core pins The pins mentioned in the table, read from left to right, have to be inserted from outside to inside on the cylinder core. 1. Please insert core pins in the cor- rect position.

22 Masterkey wafers MK wafers are used to permit locking variations in accordance with the specified locking plan. A lock cylinder without MK wafers can only be locked by one key, while a lock cylinder with MK wafers can be locked by different keys. You can use the figures in the cylinder assembly fittings table to identify which and how many MK wafers you must use. The figures that are listed vertically beneath a core pin number (in grey) tell you which gradations are required for the relevant core pin in the cylinder. As can be seen from the table, a double gradation (MK gradation) is always allowed for each pin position in locking systems. Once defined, the relevant even (0, 2, 4, 6) or odd (1, 3, 5, 7) value for each pin position cannot be changed. The mounting di- rection of the MK wafers is not important. MK wafers 0 3 1 4 1 6 2 5 4 5 6 P1 P2 P3 P4 P5 P6 Fig. 14: Masterkey wafers MK wafers are 0.8 mm, 1.6 or 2.4 mm long. One MK gradation corresponds to 0.8 mm. Here: You must place 3 MK wafers (2,4,6) on the first core pin (0). As there is one MK gradation between each of the figures (0-2; 2-4; 4-6), you must insert 3 MK wafers with a length of 0.8 mm here. On the second core pin (3) you must in- sert 1 MK wafer with a length of 0.8 mm (one MK gradation 3-5). Do not place any MK wafers on the third (1) and fourth core pin (2) in this case. You must place 1 MK wafer 1.6 mm long on the fifth core pin (1), as there are two MK gradations here (1-5). Please do not add any HS discs to the sixth core pin (6) in this case.

23 Profile control pins Profile control pins 0 3 1 4 1 6 Profile: 2 5 089B 4 5 6 Type and number of the profile control pins can be identified from the specifica- tion of the profile in the assembly super- structure. 1 2 3 4 5 A 6 7 8 9 0 B Fig. 15: Numbering of profile pins Borings for profile control pins are num- bered: Left: 1, 2, 3, 4, 5, A Right: 6, 7, 8, 9, 0, B Sample: 0,8,9,B 1. Please insert the respective profile control pins into the boring with tip ahead and make sure they do not fall out.

24 Insertion of the cylinder core into cylinder body Caution! Please make sure that the cylinder body is filled with the appro- priate pins and springs before you insert the filled cylinder core into the body. To prevent a fall out of core pins please use a soft pad. If neces- sary, rotate the body as illustrated in fig. 16 to avoid that the profile pins will fall out of the core. When assembling cylinder type KL, please fol- low the instructions beginning on page 34. When assembling type 555, please follow the instructions beginning on page 39. When assembling type 382, please follow the instructions beginning on page 37. Fig. 16: Core into body 1. Carefully insert the core with the key channel upwards into the cylinder body. Fig. 17: Remove assembly clam and turn core 2. Please protect the core from fall out and remove the assembly clam. 3. Please turn the cylinder core until the pins fall into the respective borings. Caution! The cylinder core is not yet fixed by security rings. If you insert the key the core may be pulled out from the body again and the pins will fall out. In such an event core and body have to be completely re-filled.

25 Type 333 This chapter describes the assembly of the cam with coupling for type 333. Requirements: 2 matching keys, 1 coupling (502154), cam (218228 008), 2 security rings (202335F) for the cam, security ring (202335F) for each extended side (op- tional), 1 pliers (263629) for the cam, 1 pliers (261669) for the extension piece (op- tional). Caution! The cylinder cores are not yet fixed by security rings. If you in- sert the keys the cores may be pulled out completely from body again and the pins will fall out. In such an event cores and body have to be completely re-filled. Fig. 18: Placing cores 1. Please insert a matching key on both sides. 2. Please turn key gently. 3. Please pull out cylinder cores to such an extent until cores or core exten- sion pieces provide a flush fit inter- nally with the cylinder body. Fig. 19: Insertion of cam with coupling 4. Please insert the coupling accurately fitting into the cam. 5. Please insert the cam with coupling in the centre of the cylinder body. 6. Please hold the cam in such a posi- tion that it provides flush fit with the cylinder body at top and overlaps lat- erally a little at the bottom.

26 Caution! Please align security rings always in such a direction that the flat side of the security rings point at the cam. Fig. 20: Attaching security rings 7. Please push back the cores into the cylinder body. 8. Please turn the cores into their initial position and pull out keys while fas- tening the cores. 9. Please bend the security rings gently apart. 10. Please insert the security rings in the respective positions. 11. Please press the security rings to- gether with the appropriate pincers.

27 Type 333H This chapter describes the assembly of the cam and the end piece as well as the po- sitioning of the cam for type 333H. Requirements: 1 matching key, 1 end piece (204217), 1 cam (218426 008), 2 secu- rity rings (202335F) for the cam, 1 security ring (202335F) for the extended side (op- tional), 1 pliers (263629) for the cam, 1 pliers (261669) for the extension piece (op- tional). Caution! The cylinder core is not yet fixed by the security ring. If you in- sert the key the core may be pulled out completely from the body again and the pins will fall out. In such an event core and body have to be completely re-filled. ! ! Fig. 21: Insertion of cam and end piece 1. Please insert a matching key. 2. Please turn key gently. 3. Please pull out the cylinder cores to such an extent until core or core ex- tension piece provides a flush fit in- ternally with the cylinder body. 4. Please insert the cam into the cylin- der body in such a way that the open- ing with the spring pin points towards the end piece. 5. Please hold the cam in such a posi- tion that it provides flush fit with the cylinder body at top and overlaps lat- erally a little at the bottom. 6. Please push the core back into the cylinder body. 7. Please turn the core into its initial po- sition and pull out the key while fas- tening the core. 8. Please insert the end piece into the cylinder body in such a way the spring pin of the cam slides over the chamfered part of the end piece.

28 Caution! Please always align security rings in such a position that the flat side of the security rings points towards the cam. Fig. 22: Attaching security rings 9. Please push the core back into the cylinder body. 10. Please turn the core into its initial po- sition and pull out the key while fas- tening the core. 11. Please bend security rings gently apart. 12. Please insert security rings into the respective positions. 13. Please press the security rings to- gether with the appropriate pincers. Adjusting cam The cam may be adjusted in eight different positions as required. Fig. 23: Adjustment of cam 14. Please pull down the spring pin of the cam using a blunt object. 15. Please align cam at the required posi- tion.

29 Type 333T This chapter describes the assembly of cam with coupling for type 333T. (Lockable with key inserted on both sides) Requirements: 2 matching keys, 1 coupling (235860), 1 cam (235855 008), 2 security rings (202335F) for the cam, security ring (202335F) for each extended side (op- tional), 1 pliers (263629) for the cam, 1 pliers (261669) for the extension piece (op- tional). Caution! The cylinder cores are not yet fixed by security rings. If you in- sert the keys the cores may be pulled out completely from body again and the pins will fall out. In such an event cores and body have to be completely re-filled. Fig. 24: Positioning cores 1. Please insert a matching key on both sides. 2. Please turn the keys gently. 3. Please pull out cylinder cores to such an extent until cores or core exten- sion pieces in the cam groove provide a flush fit with the cylinder body. Fig. 25: Adjust coupling Note! When assembling the coupling (double entry) in the lock stud you must take care that both discs of the coupling are congruent with each other. At first, the cou- pling is inserted into the lock stud together with the cop- per-coloured discs. The flat side of the disc must point upwards.

30 Fig. 26: Insertion of cam and coupling 4. Please insert the coupling accurately fitting into the cam. 5. Please insert the cam with the cou- pling into the centre of the cylinder body. 6. Please hold the cam in such a posi- tion that it provides flush fit with the cylinder body at top and overlaps lat- erally a little at the bottom. Caution! Please always align security rings in such a way that the flat side of the security rings point towards the cam. Fig. 27: Insertion of security rings 7. Please push cores back into the cyl- inder body. 8. Please turn the cores into their initial position and pull out the keys by fas- tening the cores. 9. Please bend security rings gently apart. 10. Please insert security rings into the respective positions. 11. Please press the security rings to- gether with the appropriate pincers.

31 Type 333K This chapter describes the assembly of the cam with stud for the type 333K. Type KL with knob must be assembled in the same way. Requirements: 1 matching key, 1 cam (235855), 2 security rings (202335F) for the cam, 1 security ring (202335F) for each extended side (optional), 1 stud axis (de- pending on the length), 1 spiral pin (099434), 1 coupling (220895), 1 carrier plate (220897F 002), 1 cone pin (236497) 1 compression spring (215230), 1 pliers (261669) for the cam, 1 pliers (261669) for the extension piece (optional). When mounting type KL with knob, you need the following: 1 cam (509293 008) and 1 stud axis (509393). Caution! The cylinder core is not yet fixed by the security ring. If you in- sert the key the core may be pulled out completely from body again and the pins will fall out. In such an event core and body have to be com- pletely re-filled. Fig. 28: Insertion of cam 1. Please insert a proper key. 2. Please turn key gently. 3. Please pull out the cylinder core to such an extent until the core or the core extension piece provides a flush fit internally with the cylinder body. 4. Please insert cam into the cylinder body.

32 Caution! Please always align security rings so that the flat side of the se- curity rings points towards the cam. Fig. 29: Attaching security rings for core (with extension piece) 5. Please hold the cam in such a posi- tion that it provides flush fit with the cylinder body at top and overlaps lat- erally a little at the bottom. 6. Please push the core back into the cylinder body. 7. Please turn the core into its initial po- sition and pull out the key while fas- tening the core. 8. Please bend the security rings gently apart. 9. Please insert security rings in the re- spective positions. 10. Please protect the core against fall out. 11. Please press security rings together with the appropriate pincers. Note! If you are not sure about the boring to fix the stud on a stud axis with several borings, please measure directly at the cylinder body. Please insert axis without stud into the cylinder body. Please use the first boring you see that is outside. Fig. 30: Fixing of knob 12. Please spray knob axis gently with the service spray provided by DOM. 13. Please insert knob axis in such a way that the boring on the axis provides flush fit with the boring in the knob. 14. Please insert the spiral pin into the boring of the knob. 15. Please beat the spiral pin completely into the boring without producing any damages of the knob.

33 Fig. 31: Filling of knob axis 16. Please insert the compression spring first into the knob axis before you in- sert the cone pin. 17. Please insert the carrier plate into the coupling now. 18. Please carefully insert coupling and carrier plate into the knob axis. Caution! Please always align the security rings so that the flat side of the security rings points towards the cam. Fig. 32: Insertion of knob axis 19. Please insert the filled stud axis into the cylinder body. 20. Please protect the stud against fall out. 21. Please bend the security ring gently apart. 22. Please insert the security ring in the respective position. 23. Please press the security ring to- gether with the appropriate pincers.

34 Type 333KL This chapter describes the assembly of the cylinder cores and the lock stud with coupling for type 333KL. When assembling type KL with knob, please follow the in- structions on page 31. Requirements: 2 filled cylinder cores, 1 follower (266009), 1 coupling (standard 502154 or double entry 235860), 1 cam (standard 509292 008 or double entry 509293 008), 1 cylinder pin (27/35: standard 207102 or double entry 510598 011; 27/40: standard 510361 or double entry 510599 011), 1 security ring (202335F) for the longer side, 1 security ring (214340F) for the shorter side, 1 pliers (263629) for the cam, 1 pliers (265776) for the security ring (214340F). Note! First, you must assemble the long side. You have already filled the cylinder core and inserted the cylinder pin (standard 207102 or double entry 510598 011) into the cylinder core. When assembling an extended cylinder (27/40), you have already inserted the cylinder pin (standard 510361 or double entry 510599 011). Fig. 33: Cylinder pin double entry 27/35 Note! Cylinder 27/35 double entry: Insert the cylinder pin 510598 011 into the core, the flat side pointing in the direction of the coupling. 4 mm Fig. 34: Insert core on the long side 1. Apply the cylinder core to the as- sembly bar in a way that the larger cut-out (4 mm) shows to the front. 2. Please insert the cylinder core into the cylinder body pressing out the assembly bar backwards. 3. Leave the cylinder core in this posi- tion (do not rotate).

35 Fig. 35: Rotate short core 4. Now fill the short side of the body ac- cording to the instructions on page 13 and insert the filled core according to the instructions on page 24ff. 5. Remove the assembly bracket. 6. Now adjust the short core in a way that the larger cut-out is flush with the cut-out of the long core. Fig. 36: Positioning cores 7. Please pull out cylinder cores to such an extent until cores in the cam groove provide a flush fit with the cyl- inder body. Fig. 37: Insertion of cam 8. Please insert the coupling accurately fitting into the cam. 9. Please insert the cam with the cou- pling into the centre of the cylinder body. 10. Please hold the cam in such a posi- tion that it provides flush fit with the cylinder body at top and overlaps lat- erally a little at the bottom. 11. Please push cores back into the cyl- inder body. 12. Rotate the lock stud until the coupling engages with the lock stud. Caution! Please always align security rings in such a way that the flat side of the security rings point towards the cam.

36 Fig. 38: Insertion of security rings 13. After having assembled the lock stud, please rotate the long core counter- clockwise and the short core clock- wise into removing position. 14. Please bend security rings gently apart. 15. Insert the security ring (202335F) at the longer side. 16. Insert the security ring (214340F) at the shorter side in a way that the stud will engage with the groove (4 mm). 17. Please press the security rings to- gether with the appropriate pincers.

37 Type 382 This chapter describes the assembly of the knurled pin and the lever. Requirements: 1 filled cylinder core with assembly bushing (266674), 1 matching key, 1 lever (200013), 1 knurled pin (242081), 2 hexagon nuts core (201306), 1 hexagon nut body (201320), 2 open-jawed wrenches SW14 and SW30. Note! You have already filled the core and an assembly bushing secures the core pins. The assembly bracket is still at the body and secures the body pins. Fig. 39: Insert core 1. Apply the core to the cylinder body. 2. Insert the cylinder core into the cylin- der body that it is precisely fitting. The assembly bushing is stripped off. 3. Remove the assembly bracket and rotate the cylinder core clockwise un- til the pins fall into the provided bores. A B Fig. 40: Adjust closing direction and attach lever 4. Please set the required closing direction with the knurled pin. closing clockwise: Please insert the knurled pin into the vertical boring above. closing anti-clockwise: Please insert the knurled pin on the left side whilst facing the DOM-logo. 5. Please push the lever on the cylinder core from behind in the position required.

38 Fig. 41: Fastening and fixing lever 6. Please fasten the lever with a hex- agonal nut SW 14 (hand-tight). 7. Please fix the hexagonal nut by a second hexagonal nut SW 14 (hand- tight). Fig. 42: Assembling cylinder 8. Please insert the cylinder at the re- spective position and fasten it with a hexagonal nut SW 30 (hand-tight)

39 Type 555 This chapter describes the final assembly of the body as well as the assembly of the engaging bar. Requirements: 1 filled cylinder core with assembly bushing (266674), 1 follower (260009), 1 rosette 555P (233617); 1 rosette 555R: (200928), 1 barrel 555R (201695), 1 compression spring (202076), 1 pin (227698), 1 engaging bar (227690), 1 engaging disc (227603), 1 round nut (237599), 1 attaching plate (201624), 2 coun- tersunk screws (200927), Note! You did already fill the core and An assembly bushing secures the core pins. The follower is still inside the cylinder body. An assembly with assembly clam cannot be performed due to the cylinder form. Fig. 43: Insert core 1. Please put the threaded side of the cylinder core into position on the fol- lower. 2. Insert the cylinder core into the cylin- der body. The assembly bushing is stripped off and the assembly bar is pressed out backwards. 3. Please turn the cylinder core until the body pins will be pushed into the re- spective borings. Fig. 44: Fastening engaging bar 4. Please push the rosette (with barrel at 555R) over the cylinder body. 5. Please insert the compressing spring and the pin into the boring of the cyl- inder core. 6. Please push the engaging disc and the round nut on the engaging bar. 7. Please fasten the engaging bar using a round nut at the cylinder core either horizontally or vertically de- pending on its use. The pin will be pushed into the recess of the engag- ing disk by the compression spring.

40 Fig. 45: Assembling cylinder 8. Please insert cylinder body in the re- spective position and fasten it to the attaching plate by using countersunk screws (hand-tight).

41 Type 777 This chapter describes the final assembly of the padlock. Requirements: 1 matching key, 1 engaging piece (229303), 1 bolt (217102), 1 screwdriver for recessed head screws. Note! You did already insert the core in the body and fastened it with a security ring (202335F). Fig. 46: Positioning engaging piece 1. Please insert a matching key into the cylinder core. 2. Please hold the core body as shown in Fig. 45 and insert engaging piece accurately fitting from behind into the cylinder core. Caution! The shackle always has to be closed if the core body is not in- side the padlock. Otherwise the fixed spring elements may get disen- gaged and have to be re-assembled. Fig. 47: Insert lock barrel 3. Please insert the core body into the padlock with closed shackle.

42 Fig. 48: Positioning lock barrel 4. Please move the key gently until the lock barrel can be inserted completely into the padlock. 5. Please permanently protect the lock barrel against fall out and open the shackle. Fig. 49: Fastening lock barrel 6. Please keep protecting the lock barrel against fall out. 7. Please put on the screw in the shackle opening and fix the lock bar- rel with the screw (hand-tight).

Storage/Maintenance If the DOM locking cylinders or several components are to be stored for a prolonged period of time before assembly or after use, store it dry and dust-free in the original packaging. Caution! Material defect because of improper lubricants! Please periodi- cally lubricate and maintain the lock cylinder using DOM service-spray exclusively. Disposal Please note that DOM locking cylinders partially consists of high quality metallic components that have to be disposed of in a specific way. Always comply with all customary provisions for the protection of the environment when disposing of them. You can also send the components of your DOM locking cylinder back to the manu- facturer.

• 6 spring mounted, massive tumblers in axial order at each lock side • Consisting of 12 sectionally graded core and body pins • Massive pin tumblers with a minimum diameter of 2.7 mm, made of hard bronze / steel, hardened and chemically nickel-plated • Smallest lock unit with the pin tumblers, massive solid pin with a minimum height of 0.8 mm • Waisted core and body pins • Truncated conical pin heads for securing the block and lock function of the clo- sure mechanism • One-piece cylinder body made of massive brass, surface electro-plated in sev- eral steps, high protection against corrosion, optional modular design • Cylinder core made of massive brass, one-piece, with a minimum diameter of 13 mm • Curved core head with guide funnel and core head groove for the positive trans- mission of torque during opening and closing. • Paracentric core and key profile in two parts • One-piece key bit made of sintered steel • Key made of nickel silver, free of corrosion • Vertical keyway • Up to 18-fold lock authorisation query for each individual key • Uniform surface of the key with optimised angled cuts of the flank angles • Trademark protection • Resistant against impact picking by modified shape of the tumbler pins

• Locking security category 6 according to DIN EN 1303 04/2005 • Waisted core and body pins • 6 massive pin tumblers with a minimum diameter of 2.7 mm Optionally available additional locking units • Increased bore and core pull protection by hard metal pins which are arranged on several levels in cylinder bodies and cylinder core • Modular technology with increased separation protection • Drilling resistance category 2 according to DIN EN 1303 04/2005

the delivery item to the customer. The statutory periods of limitation shall remain valid for claims for damages on the part of the customer for other reasons than defects of the delivery item as well as with regard to the customer’s rights in the case of a fraudulent concealment of defects or wilfully caused defects. The limitation provisions of § 479 German Civil Code shall remain unaffected.

client : master key systems commission : central master key systems key system: central locking systems system: A B 1 2 3 4 5 6 7 8 9 10 11 12 13 X = Gruppen schließt, I schließt Z bzw M, G = Gleichschließung Pos. Fb. Type Key quantity Cyl. Quantity Key Number. Door-or room description Length All relevant information to this system, keys and its orders is provided in the work sheet included.

these assembly instructions, please contact one of the branch offices in your country directly. Published by DOM Sicherheitstechnik GmbH & Co. KG, 50301 Brühl This documentation may not be reproduced, stored, transmitted or translated in any form or via any medium, in whole or in part, without the prior permission in writing of DOM Sicherheitstechnik GmbH & Co. KG. Important information This documentation is updated at regular intervals. The publisher will always be grateful for the communication of possible errors or suggestions for this documenta- tion. © DOM Sicherheitstechnik GmbH & Co. KG, 50301 Brühl