Pro-Lok Blue Punch - The Locksmith Security Association
Contents
1. INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT 3 Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from RIGHT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Schlage Everest B cuts tip to bow 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of each cut in Key Gauge Schlage Everest E Test in cylinder BP201S8CED Schlage Everest D Schlage Everest D Key sections D120 D123 D124 D134 D135 D145 D234 D235 D245 D345 and all other keys with D 3 digits NOTE For reliable bittings yu SHOULD USE SCHLAGE Factory Original Keyblanks or high quality blanks from reliable aftermarket manufacturers are acceptable in some keyways If the machine is not cutting2. 655 N Hariton St Orange CA 92868 tel 714 633 0681 fax 714 633 0470 7 E Corbin C70 Dexter Master Falcon ia Kwikset Schlage Weslock THE BLUE PUNCH KEY MACHINE This Blue Punch Key Machine is heavy duty and built to last Each machine is a dedicated punch machine designed to provide factory original keys Creates keys with the speed of a duplicator The Blue Punch is fast extremely accurate and easy to use The key machine is set up at the factory to provide automatic spacing and depth The Blue Punch is an ideal key machine for the commercial locksmith hotels schools and other institutions Fast and easy to use this key machine is preci sion machined to the tightest tolerances Portable and dependable hand operated no electrical outlet needed The professional s clear choice The FASTEST and EASIEST punch machine on the market KURCHUNK KURCHUNK Any locksmith who has been in the business for any amount of time recognizes that sound Punching a key with a bench top code cutter produces a sound unique in our industry In fact the familiar sound of the Blue Punch goes back to the 1960 s Punching the cuts on a key instead of grinding is nothing new but it s a simple concept that has made a lot of locksmiths a lot of money At PRO LOK the idea of punching original code keys is alive and well The company manufactures the Blue Punch Key Machine As the lead
3. L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Falcon Weiser cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required Falcon amp Weiser 8 Remove key check depth of each cut in Key Gauge Test in cylinder BP201IC A2 Standard Interchangeable Core Best small format I C A thru R TA thru TE W Falcon small format I C A thru R TA thru TE W Arrow small format I C 1A thru 4D Note A3 amp A4 code bars are available for purchase Depth adjust ment will be necessary when changing code bars from A2 to A3 or A4 Dedicated ICA3 amp ICA4 machines available also Specific Exclusions Arrow Flexcore Kaba Peaks Insta Key Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS R
4. in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of each cut in Key Gauge Arrow Flexcore Test in cylinder BP201C7O CORBIN C70 Most popular Corbin System 70 Keyways 59 series A1 A2 B1 B2 D2 60 series 6 pin Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine ME Y 2 With handle up move Die Carriage to the far LEFT a zr 3 Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the die and tighten L handle Note Corbin cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first po
5. BP201SCED Schlage Everest D BP201SCRV Schlage Reverse BP201WK Weslock Arrow Flexcore 51 52 53 54 61 81 83 84 Will cut A3 amp A4 with purchase of code Most Popular Corbin System 70 59 Series A1 A2 B1 B2 D2 60 Series 6 pin All Dexter Cylinders Master Door Locks Falcon Standard non 1 Will not cut 8 or 9 depths All Weiser Cylinders A2 Standard I C Interchangeable Core Best Small Format I C A R TA TE W Falcon Small Format I C A R TA TE W Arrow Small Format I C D Exclusions Arrow Flexcore Kaba Peaks Insta Key A3 System Interchangeable Core A4 System Interchangeable Core Kwikset Standard Titan will not cut square first cut Yale Residential Schlage Obverse key sections including 1 C CE E EF F FG G H J K L L aftermarket only Primus same as obverse except a P is added CP CEP EP etc Everest C including 1 C123 C124 C126 C135 C145 Everest Primus uses same names Exclusions Numbered Key Sections Quad Key Sections Reverse Key Sections Everest B Everest D Schlage Everest B B123 B125 B234 B235 and all others with a B 3 digits Will cut A3 amp A4 with purchase of code bar Schlage Everest D D120 D123 D124 D134 D135 D145 D234 D235 D245 D345 and all others with a D 3 digits Schlage Reverse Key Sections D DQ Q QS S T U Vj W amp Y All Weslock Cylinders BP207 Diagram N ee m HAND
6. accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far RIGHT 3 Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from RIGHT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Schlage Everest D cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7T Select depth of second position Cut and repeat operation for each depth cut number required Schlage Everest D 8 Remove key check depth of each cut in Key Gauge Test in cylinder BP20iISCRV SCHLAGE REVERSE e Schlage Reverse Sections D DQ Q QS S ST V W amp Y Note For reliable bittings you SHOULD USE Factory Original Keyblanks or high quality blanks from reliable aftermarket manufacturer
7. it in for a factory conversion Includes All parts normally required to convert from one style to another top jaw handle assembly upgrade finish hardware re adjustment to factory specifications and all labor Any repair or replacement of other parts will be at an additional charge 90 Day War ranty parts and labor BPRBLD Factory Rebuild Includes dis assembly cleaning lubricating a completely new engine finish hardware re adjustment to factory specifications and all labor Does not include casted parts or code bar This service is done on older Blue Punch machines regardless of who manufactured them or how they old are 90 Day Warranty parts and labor ZBP500 ASSY Top Jaw Handle Assembly Upgrade New improved adjustable ratchet lever handle design and installation hardware Advantages of the upgrade include easier key clamping clamps key tighter and a heavy duty top jaw 3 times heavier than the old style Available for all styles of Blue Punch Machines ZBP500 ARFC ASSY Top jaw L handle assembly upgrade for BP201ARFC ZBP500 C70 ASSY Top jaw L handle assembly upgrade for BP201C70 ZBP500 FW ASSY Top jaw L handle assembly upgrade for BP201FW KW ZBP500 IC ASSY Top jaw L handle assembly upgrade for BP201IC DE WK ZBP500 SC ASSY Top jaw L handle assembly upgrade for BP201SC Contact PRO LOK for any service or technical questions at 714 633 0681 or visit our website at www pro lok com The Killer
8. manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT 3 Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the die and tighten L handle Note Weslock cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required Wleslock 8 Remove key check depth of each cut in Key Gauge Test in cylinder 7 Basic Operation b 1 Install code bar from left side of machine see photo 1 2 Slide code bar to desired cut depth for first cut 3 With handle up move die carriage to the far a RIGH
9. turning the SCrew 4 Let go of the lever and it snaps back into engagement with the screw REMOVING THE L HANDLE 1 Remove the 1 handle assembly by inserting a 3mm Allen wrench in top screw to hold L handle screw 2 Rotate the L handle counter clockwise to the 9 o clock position 3 Remove Allen wrench and lift the 1 handle and return to the 3 o clock position 4 Release the 1 handle re insert Allen wrench and continue this process of rotating counter clock wise lifting rotating clockwise releasing until the 1 handle is removed from the machine Remember to remove the Allen wrench from screw on each clockwise rotation RE INSTALLING THE L HANDLE 1 Install the top jaw so that the end with the longer angled portion is toward you The end with the shorter angle has a lip to engage in the milling of the key section 2 Assemble the top jaw washer spring handle 3 Place screw in position on the bottom jaw 4 With the L handle lever to the right use a 3mm Allen wrench to hold the screw in position 5 Rotate the handle clockwise to tighten 6 Remove Allen wrench 7 Lift the L handle and rotate counter clockwise 8 Release L handle 9 Rotate L handle clockwise to tighten 10 Repeat until tight 11 To adjust the L handle s final position and rotation you will need to clamp a sample key or key blank of the key section you plan to cut
10. 45 If you are a commercial locksmith and need to cut a variety of Schlage key sections daily you may find the continuous lever adjustment cumber some On most machines the lever must be specifically adjusted for each of the three clamping positions See Drawing 5 to notice the different positions of the top jaw required to engage the grooves and seat the different shapes of Schlage key sections properly 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 to allow enough travel in the top jaw to accommodate the difference in thickness between Classic and Everest key sections and the angles at which the jaw sits The original red knob is more versatile when cutting multiple Schlage key sections daily Simply tighten it down 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 Tips for cutting Everest Key After you have cut several keys of each key section the proce xs Loosen Knob dure will be automatic FG GH AKL but for your first few keys please observe these details if and Push Jow 4 Toward tap ot Key DRAWING 5 1 Push the die carriage all the way to the right before you insert a key blank If you clamp an Everest key before moving the carriage its large
11. 9 Using a 1 8 Allen wrench loosen the 2 screws on the depth adjustment plate 1 4 turn See photo 4 10 Re insert the code bar to the depth cut 5 See photo 5 1 Using a key blank head standard head screwdriver in the slot above the screws on the depth adjustment plate lift the slide block to raise the key blank cut flush against the punch See photo 5 12 Using a 1 8 Allen wrench re tighten the 2 screws in the depth adjustment plate about 1 4 turn 13 Remove the code bar Remove the key blank Remove the screwdriver from the back of the handle 14 Loosen the top right top plate screw Put top plate back in proper position Re install the 4 top plate screws 15 Re install the top jaw handle assembly 16 Check depth adjustment accu racy with a micrometer see photo 26 BLUE PUNCH L HANDLE ASSEMBLY USING THE 1 HANDLE ASSEMBLY PRO LOK has installed the upgraded L handle to clamp the key blank on your Blue Punch ma chine The 1 handle assembly is a ratcheting handle The L handle allows for easier and quicker key clamping and unclamping of key blanks than the old style red knob HOW TO USE THE L HANDLE 1 The cap screw inside the clutching lever of the 1 handle is spring loaded 2 Lift the lever against spring pressure to disengage it from the screw 3 While disengaged you should be able to swing the lever to the left or right without
12. Jig What makes the PRO LOK Killer Jig so special ZINJIG KJ Fe MUR DIRE A i defen a iia Lac wai J xj E ate E IT PRO LOK decided to design our new Killer Jig for many reasons We felt that a profes sional high quality jig was needed that was both light in actual weight while maintaining the high quality that professional installers expect Also versatility and speed were important qualities that we wanted to incorporate into our design As a result PRO LOK is proud of our latest addition to our installation tool line of products Other Products Installation The new jig incorporates unique Cuts a lock mortise in under 5 minutes Quick Change Cutters which allow the cutters to be changed in seconds without remov ing the jig from the door This means that both the full lock body and face plate can be cut out with ease The mortise hole is automatically centered on EI T m the door and accurate results Masa a SE are obtained every time No other combination of tools can produce such fast and accurate mortise installations The jig and its precision cutters will cut a mortise in hard wood soft wood composite doors and with the use of special cutters aluminum doors as well all in under five minutes Who can install a vertical rod panic bar and outside trim in less than 1 hour You can with the PRO LOK IN Series Templates Easy to Use fast pr
13. LE L HANDLE TOP JAW b s KEY GAUGE CODE BAR UN e SS ace PA SN Ye DIE CARRIAGE BOTIOM JAW COVER PLA TE DEPTH CUT NUMBER BP201ARFC Arrow Flexcore Arrow Flexcore A2 System 51 52 53 54 61 81 83 84 Note A3 amp A4 code bars are available for purchase Depth adjustment will be necessary when changing code bars from A2 to A3 or A4 Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far RIGHT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the tip of the key against the tip stop on the bottom jaw and tighten L handle Note Arrow Flexcore cuts tip to bow 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way
14. T for Schlage and I C b LEFT for all others 4 Loosen top jaw by rotating the E handle counter clockwise 5 Place the key in the jaw see photo 2 from the a RIGHT for Schlage and I C b LEFT for all others 6 Locate the key blank milling in the groove on the bottom side of the top jaw see photo 3 Slide the key blank in as far as possible Tighten handle by rotating clock wise 8 Depress the handle to cut the first cut see photo 4 9 Slide the code bar to next depth desired Spacing is automatic 10 Depress handle Spacing Adjustment INstructions 1 Remove the code bar from the ma chine to allow adequate working room in the engine area 2 Remove the L handle assembly see photo 1 by inserting a 3mm Allen wrench in top screw to hold L handle screw Rotate the L handle counter clockwise to the 9 o clock position Remove Allen wrench and lift the L handle and return to the o clock position Release the L handle and continue this process of rotating counter clockwise lifting rotating clockwise releasing until the handle is removed from the ma chine Remember to remove the Allen wrench from screw on each clockwise rotation 3 Remove top jaw See photo 1 4 Loosen the 2 Allen head cap screws 1 complete turn see photo 2 with a 5 32 Allen wrench on the bottom jaw in order to allow play in the bottom jaw to adjust 5 Move the
15. bow may prevent the carriage from travelling far enough to let you make the first cut in the right position You will begin in cut position 2 and mis cut the key 2 Closely observe the AXE C124 and C135 have Ihe position of C145 proper engagement i grocwes Be sune ow 2 M en in veio of the top jaw into the engages anto a groove zr and push the jaw toward the cutter 50 it will engage the groove securely key section If the jaw clamps on the surface of a rib or into the very bottom relief in an Everest key you may mis cut the key because the jaw isn t able to square it up in the vise 3 C124 and C135 have tiny grooves Be sure jaw engages into a groove 4 The position of C145 s groove requires you to loosen the knob and push the jaw toward the cutter so it will engage the groove securely 2015 Schlage Small Format Everest B e Schlage Everest B Key sections A2 System B123 B125 B234 B235 and all other keys with B 3 digits Note A3 amp A4 code bars are available for purchase Depth adjustment will be necessary when changing code bars from A2 to A3 or A4 NOTE For reliable bittings you SHOULD USE SCHLAGE Factory Original Keyblanks or high quality blanks from reliable aftermarket manufacturers are acceptable in some keyways If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance
16. carriage all the way to the right for SC and IC to the left for all others NOTE There is a spacer shim under the bottom jaw Be sure not to displace it Make sure that the shim is not sticking out on either side of the bottom jaw Adjust shim as neces sary Depress the Blue Punch handle all the see photo 3 way and insert a wedge to keep the handle depressed while you are working A screwdriver handle works well for this purpose Insert screwdriver handle between the two handle springs located at the back of the handle Place the original sample key provided with your machine in the bottom jaw see photo 4 Locate the firstcut in the punch Slide the code bar in the machine until the bottom jaw is flush to the key and the key is flush to the punch see photo 4 Make sure that there are no gaps between the bottom jaw the key blank and the punch Verify that the bottom jaw is flush to the key shoulder Adjust the bottom jaw left or right as necessary to create a flush fit Check bottom jaw shim to ensure that it is still completely under the bottom jaw and not sticking out on either side see photo 4 10 Re tighten the 2 Allen head cap screws on the bottom jaw 11 Remove the code bar 12 Remove screwdriver from back of handle 13 Re assemble and install the 1 handle assembly and top jaw 14 Check spacing accuracy with calipers see photo 5 Depth Adj
17. ce INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the die and tighten L handle Note Kwikset cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7T Select depth of second position Cut and repeat operation for each depth cut number required Kwikset 8 Remove key check depth of each cut in Key Gauge Test in cylinder BP201S C SCHLAGE Schlage Classic including IC Obverse key sections only C CE E EF F FG G H J K L aftermarket blanks only Primus Same key sections as obverse add P e g CP CEP EP EFP etc Schlage Everest C inlcuding IC key sections e g C123 C124 C126 C135 C145 and all other keys with C 3 digits Everest Primus uses same names Exclusions Numbered key section Quad k
18. ead all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far RIGHT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the tip of the key against the tip stop on the bottom jaw and tighten L handle Note I C cuts tip to bow 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of each cut in Key Gauge Interchangeable Test in cylinder Core BP201 KW KWIKSET e Kwikset Standard Yale Residential Titan will not cut Titan square 1st cut Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistan
19. ecise and durable We have assembled a group of installation templates that are all used with our Universal Clamp You will get exacting accuracy and finished work in the same time as it takes others just to set up Every time you use a PRO LOK template your installation time will be faster your installations more precise and professional looking Time is money The PRO LOK IN Series Templates may be the best investment you ever make Reverse templates are available for the back side of the door You can cut your time in half by not having to switch over when you are done with one side Reverse templates also prevent the back side of the door when drilling 2007 ALL RIGHTS RESERVED PRO LOK IS A REGISTERED TRADEMARK OF WEINRAUB ENTERPRISES INC
20. ey sections Reverse key sections Everest B key sections B 3 digits Everest D key sections D 4 3 digits NOTE For reliable bittings you SHOULD USE Factory Original keyblanks or high quality blanks from reliable after market manu facturers are acceptable in some keyways If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far RIGHT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from RIGHT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Schlage cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of eac
21. h cut in Key Gauge Test in cylinder SCHLAGE BLUE PUNCH INFORMATION Pro Lok has installed the upgraded 1 Handle to clamp the keyblank on your Blue Punch Machine We have also included a Red Knob assembly for your use if necessary Note that changing the clamping method has no effect on the accuracy of the machine Pro Lok changed the original design for clamping the keyblank from a red knob to a ratcheting L Handle The Handle allows for easier and quicker clamping and unclamping of keyblanks however the red knob may be easier to use in some cases Read this page to decide which method will be best for your needs When to use the L Handle If you only use your Schlage Blue Punch to cut one type of Schlage key section you can use the L Handle for faster key clamping every time How to use the L Handle The cap screw inside the clutching lever of the DRAWING 4 Handle is spring loaded Lift the lever against the Sh spring pressure to disengage it from the screw Amim HEX SOCKET While disengaged you should be able to swing the lever to the left or right without turning the t screw Let of the lever it snaps back into FINISHING engagement with the screw When using multiple ET he Agena spang WASHER Schlage key sections use this procedure to adjust Presi SPRING the L Handle for Everest keys or for Obverse E keys Removing
22. ing manufacturer of bench top punch machines PRO LOK knows why this concept is so popular because it s so simple History proves the popularity The Blue Punch started out in the late 60 s as the Codemac 101 and later became famous as the Keymak It eventually sold under the brand names Armbruster Key Punch Automatic Security Machine ASM City Punch Schlage 40126 Kwikset Keycutter 278 Falcon Weiser 1214 and a few other labels PRO LOK bought all of the tooling dies castings parts and pieces in late 1993 and began the detailed process of manufacturing this popular punch machine Sold into the market for over 30 years there are thousands of these machines out there in daily use and the demand contin ues to be strong Although cosmetically the machine looks the same today as it did 30 years ago countless technical improvements have been made to the original Blue Punch machine since the initial acquisition by PRO LOK All manufacturing is accomplished at PRO LOK s facility If you have one of the old Blue Punches needing service or repair don t just let it sit on a shelf Its a diamond in the rough Call PRO LOK for a Blue Punch Repair number We repair and rebuild doz ens of old Blue Punches each and every week Any Blue Punch by any name is eligible and can be serviced at the PRO LOK factory Whether your punch machine needs a simple repair complete rebuild brand conversion or simply cleaning and re calibration adjusting we can do i
23. irst cut position and the key is firmly clamped Choose the depth of the initial cut by sliding the code bar on the Blue Punch to the desired depth Next push the handle firmly down Pushing firmly down on the handle does two things it produces the familiar KURCHUNK sound while cutting through the blank and it automatically advances the die carriage to the next cut position Choose the second depth and push the handle down again As you choose each succeeding depth simply pushing the handle down advances it to the next position In a matter of 5 to 10 seconds an original code key has been generated It s quick easy and accurate Once you get your hands on a PRO LOK Blue Punch Machine you won t want to ever let go No more dead battery no more extension cords Position it punch it and present it to your customer Period No other punch machine on the market today comes close to the reliability speed accuracy and durability that the PRO LOK Blue Punch offers you BP CASE Protect your investment Handy amp Heavy Duty carrying case Provides easier and safer transportation for your Blue Punch Key Machine BLUE PUNCH CLASSIFICATION Blue Punch Classification BP201ARFC Arrow Flexcore bar BP201C70 Corbin C70 BP201DE Dexter Master BP201FW Falcon Weiser 2011 I C A2 System BP2011IC A3 I C System BP2011C A4 I C A4 System BP201KW Kwikset BP201SC Schlage BP201SCEB Schlage Everest B
24. most frequently BLUE PUNCH SERVICE Factory Service Your machine comes with a full 90 day warranty parts amp labor Be sure to fill out and return your enclosed warranty card along with a copy of your invoice Is your Blue Punch Key Machine not working accurately Is it just not cutting as easily as it used to Is your cutter dull Did you lose or misplace your code bar Does your machine need to be ad justed for spacing or depth If you are experiencing any of these problems call PRO LOK for fac tory service Regardless of who manufactured your machine or how old it is we can fix it up for you Return your machine for a factory rebuild and get your machine back in almost like new condition See below for your choice of repair upgrade options to choose from Prior to returning your machine call PRO LOK for a BPR Blue Punch Repair Be prepared to provide the Style of Machine Se rial of Your Machine and the Type Of Service You Are Requesting Be sure to send your code bar with your machine The machine cannot be adjusted without it BPSER Basic Service Includes dis assembly cleaning lubricating sharpen punch amp die if needed finish hardware re adjustment to factory specifications and all labor Parts needing replacement will be at an additional price 90 Day Warranty parts and labor BPCONV Conversion When you need your machine converted from one manufacturer s keyway to another i e SC to IC send
25. s are acceptable in some keyways If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Schlage Reverse cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first position Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of each cut in Key Gauge Schlage Reverse Test in cylinder 20 WESLOCK All Weslock Cylinders Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket
26. sition Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position Select depth of second position Cut and repeat operation for each depth cut number required Corbin Russwin 8 Remove key check depth of each cut in Key Gauge Test in cylinder BP201DE DEXTER amp MASTER All Dexter Cylinders Master Door Locks Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT Loosen Top Jaw by turning L handle counter clock wise 4 Place key in jaw from LEFT side Locate top jaw in Bottom Milled Groove of key 5 Place the Key Shoulder Stop against the stop on the bottom jaw and tighten L handle Note Master Dexter cuts bow to tip 6 To cut key move Code Bar to Depth Cut Number desired for the first po
27. sition Depress the handle all the way in a quick downward motion Die Carriage automatically indexes to the next key cut position as the handle returns to the upright position 7 Select depth of second position Cut and repeat operation for each depth cut number required 8 Remove key check depth of each cut in Key Gauge Dexter S Master Test in cylinder BP201FW FALCON amp WEISER All Weiser Cylinders e Falcon Standard These key blanks are very thick and use very hard mate rial Cutting 8 and 9 depths will distort the key blank A 8 or 9 depth can be achieved by cutting a 4 depth and then backspace to recut Then set the codebar at 8 or 9 depth for the desired cut This avoids punching through too much material at one time Note For reliable bittings you SHOULD USE factory original keyblanks or high quality blanks from reliable aftermarket manufacturers If the machine is not cutting accurately simple space and depth adjustments are outlined in this booklet Call the PRO LOK factory for further technical assistance INSTRUCTIONS Read all instructions carefully before cutting keys This machine has been manufactured and machined to close tolerances Adjustments should not be required as machine has been set to factory specifica tions during assembly 1 Install Code Bar from left side of machine 2 With handle up move Die Carriage to the far LEFT 3 Loosen Top Jaw by turning
28. t We ll get your machine back to a productive status rapidly A Blue Punch is available to cut Schlage Schlage Everest B Schlage Everest C Schlage Everest D Schlage Reverse Primus Best Falcon Arrow IC A2 1 IC A4 Kwikset Titan Arrow Flexcore Falcon Standard non IC Weiser Master Dexter Weslock and Corbin System C70 keyways Each Blue Punch machine is dedicated to cutting specific manufacturer s brands We have constant requests from both lock manufacturers and customers to build machines to punch other brands of keys We are currently doing research to determine the feasibility of each request Most locksmiths own or have used a punch type key machine Some have borrowed one and been reluctant to give it back to its rightful owner Portable compact and hand powered these machines can be operated in a shop service vehicle or right at the customer s door Designed for the most common commercial and residential lock and key systems these machines will punch out a key to factory specifications in a matter of just seconds The ability to generate original keys not duplicates as needed allows you to issue your customer accurate first generation keys on a simple rekey job It also quickly generates extra original code keys for a master key system as you service each door on the job site THE BLUE PUNCH KEY MACHINE Operation is amazingly simple After the key blank is lightly clamped into the jaw the machine is set to the f
29. the L Handle Handle Assembly Red Knob Assernbly Swing the lever as far to the right as it will go Lift up against spring pressure to disengage it from its screw Swing it back as far to the left as it will go and let it down to engage the screw Repeat this process as many times as necessary to unscrew the screw completely and remove the lever A 3mm hex wrench may be helpful Remove the lever spring washer and top jaw Re Installing the L Handle Unscrew the red knob washer and spring Remove the top jaw Use a 3 mm Allen wrench to start the screw Install the jaw so that 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 Assemble top jaw washer spring L Handle Reinstall on machine To adjust the lever s final position and rotation you will need to clamp a sample key or key blank of the key section you plan to cut most frequently See Drawing 4 RED Eu WASHER IOP JAW a When to use the Red Knob The L Handle upgrade was implemented prior to the release of Schlage Everest keyblanks The L Handle lever can only swing about 180 before hitting the body of the machine Unfortunately the 1 Handle 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 keys on up to the highest position required for C1
30. ustment INstructions 1 Remove L handle assembly and top jaw from machine Remove the L handle assembly by inserting a 3mm Allen wrench in top screw to hold L handle screw Rotate the L handle counter clockwise to the 9 o clock position Remove Allen wrench and lift the 1 handle and return to the 3 o clock posi tion Release the L handle and continue this process of rotating counter clockwise lifting rotat ing clockwise releasing until the L handle is removed from the machine Remember to remove the Allen wrench from screw on each clockwise rotation See photo 1 2 Loosen the top right screw on the top plate See photo 72 3 Remove the three other screws on the top plate 4 Rotate the top plate to the right 90 counter clockwise The bottom left corner of the top plate should be placed to that it is slightly overlapping the slide block See photo 2 5 Tighten the top right screw in the top plate to keep the top plate stationary while you work See photo 2 6 Advance the carriage 3 spaces 7 Depress the Blue Punch handle all the way and insert a wedge to keep the handle depressed while you are working A screw driver handle works well for this purpose Insert screwdriver handle between the two handle springs located at the back of the handle See photo 3 8 Insert the original sample key in the bottom jaw Locate the 3rd cut at the punch See photo 4
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