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Assembly

8

Assembly

Please follow the stated order and pay attention to the notes and figures.

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.

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Summary of Contents for Sigma Plus

Page 1: ...EDV Nr 298061 0 gb 08 09 Rev D Assembly Instructions Key system Sigma Plus Profile 145 ...

Page 2: ...Notes ...

Page 3: ... 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 ...

Page 4: ...Contents 2 WARRANTY 46 WORKSHEET 47 ...

Page 5: ...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 m...

Page 6: ...onents 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 instru...

Page 7: ...der 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 whe...

Page 8: ...re 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 ot...

Page 9: ...ntry 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 waf...

Page 10: ... 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 fi...

Page 11: ...tions 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 ...

Page 12: ... 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 ...

Page 13: ...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 asse...

Page 14: ... 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 ...

Page 15: ... 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 21159...

Page 16: ... 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 511...

Page 17: ...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 5092...

Page 18: ...nserted 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 spri...

Page 19: ...oading 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 ...

Page 20: ... 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 ...

Page 21: ... 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 m...

Page 22: ...am 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 ...

Page 23: ... 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 N AB AB Fig 13 Numbering of cor...

Page 24: ...ition 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...

Page 25: ...le 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 ...

Page 26: ...ctions 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 Ple...

Page 27: ...pletely 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 ins...

Page 28: ...aching 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 ...

Page 29: ...tely 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 t...

Page 30: ...ts 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 usi...

Page 31: ... 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 cou...

Page 32: ...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 secur...

Page 33: ...1669 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 ...

Page 34: ...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...

Page 35: ...rier 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 pre...

Page 36: ...76 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 3...

Page 37: ...til 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 c...

Page 38: ...wise 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 ...

Page 39: ...ns 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 knu...

Page 40: ...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 ...

Page 41: ...ue 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 ...

Page 42: ...Assembly Type 555 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 ...

Page 43: ...g 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...

Page 44: ...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 ...

Page 45: ... 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 envi...

Page 46: ...linder 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 ...

Page 47: ...ve 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 ...

Page 48: ...tutory 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 ...

Page 49: ...ntral 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 ...

Page 50: ... 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 D...

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