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Contents
1. Ne Finishing Washer GY Ingersoll Rand Security Technologies A EVER E ST Upgrading Machines With a Red Knob 1 Unscrew the old knob 2 Remove the old top jaw 3 Install the new pieces Install the jaw so the end with the longer angled portion is toward you The end with the shorter angle has a lip to engage in the groove of the key section 4 Screw on the new red knob Long Angle Upgrading Machines With a Black Lever 1 Swing the lever as far to the right as it will go Lift up against spring pressure to disengage it from its screw 2 Swing the lever back as far to the left as it will go and let it down to engage the screw 3 Repeat this process as many times as necessary to unscrew the screw completely and remove the lever A hex wrench may be helpful Remove the lever spring washer and top jaw Install the new jaw so that the end with the longer angled portion is toward you The end with the shorter angle engages the groove in the key milling 6 Reinstall the black lever or install the new red knob depending on your preference The red knob screws into place If reinstalling the black lever use an Allen wrench to start the screw then reverse the process used to remove the lever To adjust the lever s final position and rotation clamp a single key or key blank of the key section you will2. Everest M keys existed The lever can only swing about 180 before hitting the body of the machine Ifthe Blue Punch is used only to cut one type of Schlage key section the lever s travel may be set for fast secure clamping every time The black lever does not allow the top jaw to travel from its lowest position for Obverse keys to an intermediate position for clamping most of the Everest C Family keys to the highest position required for C145 Commercial locksmiths who cut a variety of Schlage key sections daily may find the continuous lever adjustment inconvenient On most machines the lever must be specifically adjusted for each of the three clamping positions Use the following procedure to back the screw out for Everest keys or to tighten the screw for Obverse keys 1 Lift the lever against spring pressure to disengage it from the screw 2 While disengaged swing the lever to the left or right without turning the screw 3 Let go of the lever and it snaps back into engagement with the screw Upgrade Package 40 074 A newly designed top jaw red knob spring finishing washer and regular washer can be obtained from your Schlage or Pro Lok distributor Changing the top vise jaw has no effect on the accuracy of the machine If the machine exhibits mechanical problems or cannot cut keys accurately please contact your Pro Lok distributor to arrange for your machine to be rebuilt lt q Red Knob
3. cut most frequently Hex Socket Lift Up Against Spring Pressure While Backing Screw Out Conventional Cylinders IN EVER EST Service Manual Tips for Cutting Everest Keys After cutting several keys of each key section the procedure will become familiar However for the first few keys please observe these important details e Push the die carriage all the way to the right before inserting a key blank If you clamp an Everest key before moving the carriage its large bow may prevent the carriage from travelling far enough to allow the first cut to be correctly positioned Cut position will begin at 2 and incorrectly cut the key Closely observe the proper engagement of the top jaw into the key section If the jaw clamps on the surface of a rib or into the very bottom relief on an Everest key the key jaw is not able to square up the blank in the vise incorrectly cutting the key C124 C145 C124 and C135 have tiny grooves Be sure jaw The position of the groove on C145 C245 and C345 engages into a groove blanks requires loosening the knob and pushing the jaw toward the cutter to securely engage the groove GY Ingersoll Rand 10 Security Technologies Service Manual L EVER EST Key Blanks Operating Keys Ip af Back 35 002 35 009 35 002 and 35 009 35 015 Standard for D Family Standard Front Back Optional Plain Bow Optional for C F
4. lever to mortise and rim cylinders These benefits make Schlage cylinder inventory flexible reduce the size and cost of inventory improve customer lead time and increase customer satisfaction With a few modular components in stock the cylinder type and finish required will always be on hand The modular cylinder accepts a tailpiece or a mortise cam Product line availability A AL B CL D H L ND S S200 Kryptonite PL KS KC and Rim standard and lockout All competitive locks that accept Everest Primus will also accept the modular cylinders Key In Knob to Modular Mortise and Rim Cylinder Conversion Modular Mortise Cylinder NM Modular Rim Cylinder 1583 474 or ee S Noam Soron P Housing cam Extension ST Part Size Part Number Number I plug Extension Cam Screw 1 2 B520 721 1 L583 474 B520 690 B520 298 Bech ee B520 722 1 L583 475 B520 690 B520 723 1 L583 474 B520 691 B590 298 erg B520 724 1 L583 475 B520 691 B590 298 Gi B520 725 1 L583 474 B520 692 B590 299 SA B520 726 1 L583 475 B520 692 B590 299 1 housing LY Ingersoll Rand 4 Security Technologies Conventional Cylinders Service Manual The following instructions assume that the reader has basic experience pinning conventional cylinders The difference with Everest M cylinders is the check pin and spring located in the specia
5. 6 8 120 34 208 Other Pins and Springs 7 270 34 307 9 135 34 209 Description Part No 8 285 34 308 Tumbler Spring C503 113 9 300 34 309 Check Pin 34 007 Check Pin Spring C603 951 Cap Pin C503 116 Cap Pin Spring C503 115 AR Ingersoll Rand Security Technologies AEVERESTT Cutting Everest Keys on the Blue Punch Handle Key Gauge p Die Carriage Er Bottom Jaw Clamp Into Groove Between Ribs Sexe Bottom Jaw_ 7 Key Stop The original version of this popular key machine was developed in the mid 1970 s Pro Lok is the most recent in the succession of companies that have manu factured the machine Even if you have what appears to be an original Schlage punch 40 126 it was made by one of the earlier companies The basic principles are the same for all versions of the machine but there are minor differences in the vise jaws which affect the machine s ability to cut Everest C Family keys Machines made before July 1999 were not designed to hold Everest keys Most of these machines have a thin top vise jaw made of stamped steel Some machines will hold Everest keys except sections with 45 in the des ignation such as C145 Even the first generation solid steel jaw was produced before Everest keys existed and must be replaced You may be able to alter your old style jaw by slightly elongating the hole so it can travel far enough to engage in C145 s groove However this solu
6. Front Cover Service Manual IN A gt Ge Ze u un Contents Juge TT e r AAA o O 1 Key Control ciar e ais 2 Open EE 2 Restricted KeywayS adds 2 SS ee ee 2 Mechanical e UE TE 3 ele rte Re le 3 elef Tele 3 Traditional CMS ias een ee a eee eee 3 Modular CAMS iii ce 3 Modular ell E A Key In Knob to Modular Mortise and Rim Cylinder Conmversion cnn nano conan o canon n rn rann ra rann rca 4 Modular Housing Interchangeabiltv A 4 Rekeying When You Have the Old Key no master keying uearrsnsnnnnnnannnnnnnnnnnannnnnnnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 MasterKeying 2 22 O 5 Rekeying When You Have No Keys uuuuru00000000000nnnnnnnnnan nun nn nun nnnnnnn ann nnnnrn nam nnnnn nn ann nnneern anne anne 6 Key Bitting Specifications cisma iia 7 Pins OS A ka scacyeuumees cuuesesscedeceucesatsleyauacceestensenteace 7 Cutting Everest Keys on the Blue Punch mncccinncnnnnnccconicnnccrrnnnrcr nn 8 Upgrading to New Top Jaw nnnanneeennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn nennen nennen nenne ernennen nennen 9 Red Knob Operation ea ee ehem 9 Black Lover Operativo lin edita ica 9 Upgrade Package dee eege eege Eegenen leede dE Eed egG e 9 Upgrading Machines With a Red knob nennen 9 Upgrading Machines With a Black Lover u een kenne 9 Tips for Cutting Everest Key 8 eege EES anna nam ann nn ann nn nn aaa ana n an aN Hrana diuna nun eEEN 10 Key Blanks iuu esuuucsn nennen ne
7. amily for C Family for C and D Families Control Keys Cut Keys ELN NEVA Ki To order cut keys Change 35 prefix to 48 or 49 48 Change keys and random or stock cut keys 49 Factory master level key including control keys 35 003 Front 35 003 Back C Family Open Keyways All Section Key C000 d Multi Section Keys C100 C200 g Multi Section Keys g Multi Section Keys in en a po 45 C135 C125 C124 C123 C234 C235 C245 C345 t keyway systems begin Keyways and Single Section Keys here and continue to the right GY Ingersoll Rand Security Technologies 11 Conventional Cylinders IN EVER EST Service Manual AR Ingersoll Rand 12 Security Technologies Service Manual IN EVER EST AR Ingersoll Rand Security Technologies 13 Conventional Cylinders IN EVER EST Service Manual AR Ingersoll Rand 14 Security Technologies Back Cover
8. aster key systems Restricted Keyways For end users who want restricted keys with patent protection Schlage offers its Everest D Family keyways Everest D Family keyways are protected by the same patents and require a letter of authorization from the end user The difference between the C and D Families is just the keyway Despite the fact that Everest D Family keyways are restricted keyways they are still serviced in the same manner as the C Family keyways However D Family restricted keys can be cut reliably on key bitting punch 40 099 because the top of the blade is not straight A The keyway for each restricted D Family job is selected by Schlage and registered to the end user Everest restricted key blanks cut keys cylinders and plugs are drop shipped directly to the end user or a location spe cifically authorized by the end user This creates positive key control by preventing dealers and distributors from having access to keys and cores without the end user s permission Conventional Cylinders Service Manual Primus Integration Primus cylinders are also available with Everest keyways The Everest Primus keys are downward compatible to operate the conventional Everest cylinders covered in this manual See the Schlage High Security Cylinders amp Key Control Service Manual SC GN 1001 for details on Everest Primus cylinders A portion of the undercut groove is milled away on all conventional Everest keys to p
9. g Otherwise hold the check pin in position with your finger or thumb while removing the setup key and inserting the new operating key Install the new pins in the plug 9 Orient the plug so it is slightly turned with respect to the shell Gently push the plug into the shell pushing the follower out 10 Test all keys for smooth operation 11 Reinstall the cam tailpiece etc aim Ingersoll Rand Security Technologies Conventional Cylinders Service Manual AEVERES TE Key Bitting Specifications The following specifications are the same for Schlage Classic keys including Primus 1 012 2 Code Card 8558 6996 C45 A for HPC 1200CM GH Code Machine 3872 pm MACS 7 Pr Increment 0 15 Progression Two Step 100 Blade Width 343 Depth Tolerance 002 0 Spacing Tolerance 001 031 Root Depths 0 335 1 320 2 305 3 290 4 275 5 260 o J 6 245 7 230 8 215 9 200 Pins and Springs Bottom Pins Master Pins Top Pins Size Length Part No Size Length Part No Size Length Part No Application 0 165 34 300 2 030 34 202 1 235 34 101 Plug total 0 1 2 3 1 180 34 301 3 045 34 203 2 200 34 102 Plug total 4 5 6 2 195 34 302 4 060 34 204 3 165 34 103 Plug total 7 8 9 3 210 34 303 5 075 34 205 4 225 34 304 6 090 34 206 5 240 34 305 7 105 34 207 6 255 34 30
10. g key and turn it slightly in either direction Gently push the plug out with a plug follower 2 Keeping the old key in the plug discard the old pins Key holds check pin in place 3 Hold the check pin in position with a finger or thumb Remove the old key and insert the setup key If you are certain that the cylinder was not previously master keyed skip to step 5 4 IMPORTANT Clear the cylinder shell of any remaining master pins If master pins remain in the shell the following problems may occur e A key cannot be inserted or removed e One or more springs may get crushed and cause a future lockout e Additional keys will operate the cylinder Slowly back the follower out of the shell Replace any weak or damaged springs Load the proper size top pin based on the plug total bottom pin any master pins A plug follower with a groove will help guide each spring and top pin into its chamber as you push the follower in from the back of the shell The 40 116 shell loading tool can make this process easier 5 Install new bottom and master pins into the plug 6 Orient the plug so it is slightly turned with respect to the shell Gently push the plug into the shell pushing the plug follower out 7 Test all keys for smooth operation 8 Reinstall the cam tailpiece etc Conventional Cylinders IN EVER EST Service Manual Rekeying When You Have No Keys When no key is available use standard locksmith techni
11. ion of this manual provides details on how to upgrade the old Blue Punch Note D Family restricted keys can be cut on a different key bitting punch 40 099 because the top of the key blade is not straight AR Ingersoll Rand Security Technologies A EVER E ST Larger Key Bow PAT 5 715 717 A N Undercut Groove Keyway and Everest Logo on Plug Face qe Hole in Cylinder Shell for Check Pin AEVERESTT Key Control Since the late 1960 s patents on keys have been used primarily to prevent unauthorized key duplication This is the case with Schlage s new Everest D Family key ways but the C Family open keyways are a major depar ture from this tradition Open Keyways Everest C Family Keyways are protected by U S utility patents 5 715 717 and 5 809 816 against unauthorized manufacture and distribution However the C Family keyways are readily available to the end user for fast and easy key duplication without any formalities All C key ways are considered open keyways which means they can be stocked and sold by all locksmiths and contract hardware dealers The purpose of the Everest C keyways is to guarantee the end user genuine Schlage quality replacement keys and to provide commercial locksmiths and contract hard ware dealers a group of keyways not available in home centers or retail key stands Everest C Family keyways are the default keyways for new Schlage m
12. l chamber on the bottom of the plug If using a key to remove the plug the key will hold both the check pin and check pin spring in place Rekeying When You Have the Old Key no master keying 1 Remove the cam tailpiece or other type of plug retainer 2 Insert the old key and turn it slightly in either direction 3 Push the plug out gently with a plug follower Ki Key holds check pin in place 4 While the key is still in the plug to hold the check pin in place discard the old pins 5 Hold the check pin in the plug with your finger or thumb Remove the old key and insert the new key 6 The new key holds check pin in place while the bottom pins are installed and the plug is put back into the shell 7 Reinstall the cam tailpiece etc Lip raises check pin and holds it in plug Master Keying The master keying capacity of full size Everest cylinders is the same as Schlage Classic cylinders 4 096 theoretical changes per keyway using two step progression The MACS is 7 When master keying Everest cylinders Schlage recommends using a setup key to reinstall the loaded plug AR Ingersoll Rand Security Technologies AEVERESTT A setup key can be made by cutting a key blank to a9 depth in all positions When the steeples between the cuts are removed the setup key can hold the check pin in place when removing the plug of a shimmed cylinder 9 Depth Key for Setup Key 1 Insert any operatin
13. nn nn E 11 Operating KO Sii is 11 Eege EE 11 UIT E ET EEE 11 G Family Open Ko WS nee en en eure ee 11 AR Ingersoll Rand Security Technologies i Conventional Cylinders IN EVER EST Service Manual AR Ingersoll Rand ii Security Technologies Conventional Cylinders Service Manual Introduction Everest M is the name given to a new family of patented key products by Schlage Everest products are distinguished by the patented undercut groove milled into the right side of the key blade Patented Undercut Ya Groove The first product in this family was the small format inter changeable core SFIC introduced in November 1998 to retrofit 7 pin Best style IC products A different service manual MS C75 is devoted to SFIC This manual covers the Schlage Everest cylinder which is available in mortise rim key in knob and key in lever versions The Everest cylinder is also available in Schlage s 23 030 full size interchangeable core Except for the keyway and special pin which checks for the lip on the side of the key section Everest cylinders are virtually identical to Schlage Classic cylinders with the C keyway which have been around since 1935 Locksmiths and users get the benefits of the new patent without the need to invest in new pin kits key machines or additional service equipment However a new top vise jaw is needed for the Blue Punch to hold all Everest C Family open key sections A separate sect
14. ques to shim the cylinder open However the check pin must be taken into account Follow these steps 1 Using a pick or key blank shim the six pins as usual After the last pin is neutralized the plug still cannot rotate or slide out because the check pin is engaged Leaving the shim in place insert a setup key with no steeples between the 9 depth deep cuts This unlocks the check pin and will also keep it from spring ing out of the plug in step 4 Use the setup key to turn the plug slightly in either direction and remove the shim For removing plug when shimming Push the plug out gently with a plug follower 5 While the setup key is still in the plug discard the old pins If you are certain that the cylinder was not previously master keyed skip to step 7 IMPORTANT Clear the cylinder shell of any remaining master pins If master pins remain in the shell the following problems may occur A key cannot be inserted or removed e One or more springs will get crushed and cause a future lockout e Additional keys will operate the cylinder Slowly back the follower out of the shell Load the proper size top pin based on the plug total bottom pin any master pins A plug follower with a groove will help guide each spring and top pin into its chamber as you push the follower in from the back of the shell The 40 116 shell loading tool can make this process easier If you are master keying leave the setup key in the plu
15. revent them from being altered to operate an Everest Primus cylinder Lip to lift check pin Lip removed to prevent Primus operation AR Ingersoll Rand Security Technologies Conventional Cylinders Service Manual A EVER E ST Mechanical Overview Tumbler Cylinder Cross Section Springs Top pins ee Shell Master Pins ILL Tailpiece de Sp Bu rit ottom Pins e Kee p WW k Locked Unlocked Plug Retainer Cap Check Pin Spring Retainer Cap Pin Check Pin Retainer Cap Pin Spring Traditional Cylinder Modular Cylinder Everest and Primus Classic Everest and Classic Lt gt Vertical 2 u Om Horizontal Traditional Cams Modular Cams Everest and Primus Classic For cylinder housing sizes 1 1 1 For cylinder housing sizes 1 1 1 1 4 112 34 1 8 3 8 5 8 E de 0 Us Mortise cylinders use the Primus cam with one screw Modular cylinder cams may be used with Classic Everest and Primus key sections Use appropriate cam for cylinder housing size AR Ingersoll Rand Security Technologies Conventional Cylinders IN EVER EST Service Manual Modular Cylinders Introduced in April 2010 the Schlage modular cylinder provides easy convertibility between key in
16. tion should only be a temporary measure until you install the 40 074 upgrade package with the properly shaped top jaw Elongate Conventional Cylinders Service Manual In the close up illustrations of the vise notice the different positions of the top jaw required to engage the grooves and seat the different shapes of Schlage key sections properly Left end of vise Obverse Key Sections C CE E EF F FG G H J K L Loosen knob and lift jaw Most Everest Key Sections C100 C120 C123 C124 C135 C150 E lt t Loosen knob and lift jaw toward top 1 of key blade Everest 45 Sections C145 C245 C345 Not only must the top jaw engage in different places up and down the side of the various key sections but the lever or knob screw must be tightened or loosened substantially Loosening and tightening the lever or knob screw allows enough travel in the top jaw to accom modate the difference in thickness between Classic and Everest key sections and to adjust for the angles at which the top jaw sits AR Ingersoll Rand Security Technologies Conventional Cylinders Service Manual Upgrading to New Top Jaw Red Knob Operation Tighten the red knob on the Obverse key sections or loosen it enough to let the top jaw move up to grab into the high groove of C145 or anything in between Black Lever Operation Pro Lok changed the red knob to a black clutching lever in 1998 before
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