Everest® full size cylinder
Contents
1. Letter Description Part no CELLET DOSEnpHen ESTEE A Pin Control C603 967 C Pin actuating C603 964 B Cylinder cap pin C603 827 D Ring actuating C603 956 The Schlage Full Size Interchangeable Core FSIC design enables the full capabilities of a Schlage masterkey system The extended tip of a control key will operate the control pin and retract the control lug by rotating the key 15 degrees of clockwise rotation FSIC equipped locks cylinders and cores are available mastekeyed or shipped 1 bitted from the factory Keyed different is not allowed By utilizing a special blank a control key can be created at any level within the system It is possible to have a control key that works the entire system as well as a control key that will only work one core Control keys must be ordered separately See Everest key blanks on page 18 and Everest 29 key blanks on page 19 for keying information Schlage Everest full size cylinder service manual 7 Modular cylinders Modular cylinders Introduced in July 2010 the Schlage modular cylinder provides easy convertibility between key in 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 t2. 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 manufactured 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 amp Everest 29 S 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 designation 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 Cl45 s amp S145 groove However this solution should only be a temporary measure until you install the 40 074 upgrade package with the properly shaped top jaw Elongate 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 Obverse Key Sections C CE E EF F FG G H J K L Left end Of vise Most Everest and
3. Everest C Family open keyways All Section Key d COOO i Multi Section Keys d C100 C200 J Multi Section Keys Jj Multi Section Keys MAS LT Ts i C134 Acie C135 C125 C124 C123 C234 C235 C245 C345 New o systems begin Keyways and Single Section Keys here and continue to the right 18 Schlage Everest full size cylinder service manual Everest 29 key blanks Everest 29 key blanks Operating keys Conventional Primus XP Primus all Primus blanks require proper authorization all Primus XP blanks require proper authorization Standard front Plain both sides Standard for all Standard front Plain both sides Standard front Plain both sides for S Family 35 272 control keys and 35 199 XP Operating 35 138 XP Control 35 199 Operating 35 138 Control 35 270 all T Family keys 35 273 XP Control 35 215 XP Operating 35 273 Control 35 215 Operating Optional for S Family Back of all except Back of all except 35 268 Operating 35 215 XP 35 215 35 269 Control 35 138 XP 35 138 6 Pin Control Back of all except 35 272 Back of 35 269 Everest 29 S Family open keyways All section key SOOO Multi section keys E S100 S200 Multi section keys r Multi section keys E 5134 S145 S135 S125 S124 5123 5234 5235 5245 5345 New master key systems begin here Stock keyway for andn expand to the right commercial sales
4. Schlage Everest full size cylinder service manual 19 About Allegion Allegion NYSE ALLE creates peace of mind by pioneering safety and security As a 2 billion provider of security solutions for homes and businesses Allegion employs more than 7 800 people and sells products in more than 120 countries across the world Allegion comprises 23 global brands including strategic brands CISA Interflex LCN Schlage and Von Duprin For more visit www allegion com apti m LCN m STEELCRAFT m VON DUPRIN AH m mH O 2014 Allegion WwW 008484 Rev 03 14 www allegion com us A L L E G O N
5. Commercial products and Schlage master key systems Restricted keyways For end users who want restricted keys with patent protection Schlage offers its Everest D and Everest 29 T Family keyways Everest D and Everest 29 T Family keyways are protected by the same patents and require a letter of authorization from the end user The difference between the C S and D T Families is just the keyway Despite the fact that D and T Family keyways are restricted keyways they are still serviced in the same manner as the C and S Family keyways D and T Family keyways can be reliably cut with the 40 099 key bitting punch Due to the design of the key blade a standard punch cannot be used T 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 specifically 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 Primus and Primus XP integration Primus and Primus XP cylinders are also available with Everest or Everest 29 keyways The Everest Primus XP and Everest 29 Primus XP keys are downward compatible to operate the conventional Everest cylinders and Everest 29 cylinders covered in this manual See the Schlage High Security Cylinders amp Key Control Service Manua
6. 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 Insert the old key and turn it slightly in either direction Push the plug out gently with a plug follower M504 548 for modular cylinders While the key is still in the plug to hold the check pin in place discard the old pins Key holds check pin in place Master keying The master keying capacity of full size Everest or Everest 29 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 or Everest 29 cylinders Schlage recommends using a setup key to reinstall the loaded plug A setup key can be made by cutting a key blank to a 9 depth in all positions When the steeples between the cuts are removed the setup key can hold the check pin in C place when removing the plug of a shimmed cylinder 1 12 Schlage For removing plug after shimming Insert any operating key and turn it slightly in either direction Gently push the plug out with a plug follower For the modular cylinder we recommend the M504 548 follower Keeping the old key in the plug discard the old pins Key holds check pin in place Hold the check
7. for clamping most of the Everest C and Everest 29 S Family keys to the highest position required for C145 and S145 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 C y Finishing Changing the top vise jaw has no Washer effect on the accuracy of the D spring machine If the machine exhibits w Washer mechanical problems or cannot cut keys accurately please contact your Pro Lok distributor to arrange for your machine to be rebuilt PL I omm 16 Schlage Everest full size cylinder service manual Upgrading machines with a red knob 1 Unscrew the old knob 2 Remove the old top jaw Long Angle 3 Install the new pieces Install the jaw so the end with the longer angled portion is toward you The end with the s
8. 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 Everest full size cylinder service manual 5 Hold the check pin in the plug with your finger or thumb Remove the old key and insert the new key The new key holds check pin in place while the bottom pins are installed and the plug is put back into the shell Reinstall the cam tailpiece etc Lip raises check pin and holds it in plug 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 One or more springs may get crushed and cause a future lockout Additional keys will operate the cylinder Using the M504 548 follower for modular cylinders slide the flat section of the follower inside the shell and rotate the flat section until it comes under the bible All the master pins will then fall out Rotate the flat section until it is opposite the bible and slide follower until about an inch is protruding from the front 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
9. 1998 to retrofit 7 pin Best style IC products Full sized Everest C and D families followed shortly after A different service manual MS C75 is devoted to SFIC Everest 29 was introduced in August 2012 with a new undercut design that is patent protected until 2029 Everest 29 R S and T families are backward compatible with Everest B C and D keyways respectively This manual covers the Schlage Everest and Everest 29 cylinders which are available in mortise rim key in knob and key in lever versions The Everest cylinders are also available in Schlage s 23 030 full size interchangeable core FSIC 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 Everest 29 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 and Everest 29 S Family open key sections A separate section of this manual provides details on how to upgrade the old Blue Punch Note D Family and T Family restricted keys can be cut ona different key bitting punch 40 099 because the top of the key blade is not straight Additionally a different service manual MS C75 is devote to SFIC products 4 Schlage Everest full size cyl
10. ANB H n Tpu ALLEGION CHLAGE F verest ful size cylinder Service manual Contents ON GY ey oa c NO ee N Introduction Key control Open keyways Restricted keyways Primus and Primus XP integration Mechanical overview Everest full size interchangeable core Modular cylinders Key in knob to modular mortise and rim cylinder conversion Tailpieces Cap Pin Locations Multiple tailpiece key in knob key in lever cylinders Tools and sales support items Keying Rekeying when you have the old key no master keying Master keying Rekeying when you have no keys Key bitting specifications Pins and springs Cutting Everest 29 keys on the blue punch Upgrading to new top jaw Red knob operation Black lever operation Upgrade package 40 074 Upgrading machines with a red knob Upgrading machines with a black lever Tios for cutting Everest and Everest 29 keys Everest key blanks Operating keys Everest C Family open keyways Everest 29 key blanks Operating keys Everest 29 S Family open keyways Introduction Introduction Everest 29 is the name given to a new family of patented key products by Schlage Everest 29 and Everest products are distinguished by the unique patented undercut groove milled into the right side of the key blade Undercut groove The first product in this family was the B family of small format interchangeable core SFIC introduced in November
11. Everest 29 Key Sections C100 C120 C123 C124 C135 C150 S100 S120 S123 S124 S135 S150 Loosen knob and lift jaw Everest and Everest 29 45 Sections C145 C245 C345 Ti HH i i y Loosen knob and lift jaw toward top of key blade S145 S245 S345 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 accommodate the difference in thickness between Classic and Everest 29 key sections and to adjust for the angles at which the top jaw sits Schlage Everest full size cylinder service manual 15 Upgrading to new top jaw 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 S145 or anything in between Black lever operation Pro Lok changed the red knob to a black clutching lever in 1998 before Everest keys existed The lever can only swing about 180 before hitting the body of the machine If the 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
12. Knob ND Levers D Knobs except 73 Keyways Product Tailpiece Orientation Part number Classic 21 000 Everest A H and D Knobs A700 031 Horizontal 40 100 Everest 29 80 216 AL Vertical A and H Orbit except 73 A301 338 Horizontal D Knob C603 524 Horizontal ND Levers N523 022 Vertical 10 Schlage Everest full size cylinder service manual Tools and sales support items Tools and sales support items Pin kit 40 119 Contains all conventional pins and springs modular follower M504 548 tweezers and M540 056 cylinder cap removal tool Plug holder 40 066 Has grooves for Primus sidebar Included in 40 070 finger pin kit Key bitting punch 40 075 Blue punch for cutting Obverse and Everest Open C family keys Key gauge 40 104 40 104 KEY GAGE 9 8 7 6 5 4 3 2 1 0 SCHLAGE O Vise jaw upgrade kit 40 074 Replaces jaw on Blue punch key machines manufactured before July 1999 to add Everest C family Capability to Obverse family key machines Schlage Everest full size cylinder service manual 11 Keying The following instructions assume that the reader has basic experience pinning conventional cylinders The difference between Everest 29 and traditional cylinders is the check pin and spring located in the special
13. ailpiece or a mortise cam Product line availability A AL B CL D H L ND S S200 Kryptonite PL KS KC Mortise and Rim All competitive locks that accept Everest Primus XP or Everest 29 Primus XP will also accept the modular cylinders Modular key in knob cylinder Modular mortise cylinder Modular rim cylinder 8 Schlage Everest full size cylinder service manual Modular cylinders Key in knob to modular mortise and rim cylinder conversion Modular housing interchangeability Housing Cam Cam screw Plug extension Part number Size Part number B520 721 We L583 474 B520 690 B520 722 11 4 L583 475 B520 690 B520 723 13 L583 474 B520 691 B590 298 B520 724 11 5 L583 475 B520 691 B590 298 B520 725 1 L583 474 B520 692 B590 299 B520 726 13 4 L583 475 B520 692 B590 299 Cam ___ N Cam Screw 1 B E L583 474 or L583 475 B520 692 SS Plug Extension Cam Screw 24 B520 299 B520 691 A Cam lt L583 474 or L583 475 A E os Plug Extension Cam Screw 72 B520 298 B520 690 i P d L583 474 or L583 475 em 134 1V4 1 housing Schlage Everest full size cylinder service manual 9 Tailpieces Tailpieces Cap Pin Locations Vertical Horizontal A700 031 A301 338 C603 524 N523 022 AL A H and A and H Orbit D
14. can make this process easier Install new bottom and master pins into the plug 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 Test all keys for smooth operation Reinstall the cam tailpiece etc Keying Rekeying when you have no keys When no key is available use standard locksmith techniques 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 2 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 springing out of the plug in step 4 3 Use the setup key to turn the plug slightly in either direction and remove the shim C For removing plug Push the plug out gently with a plug follower For the modular cylinder we recommend i after shimming the M504 548 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 6 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 One or more springs will ge
15. commended MACS 7 Increment 0 15 Progression Two Step Blade Width 343 Depth Tolerance 002 O Spacing Tolerance 001 Root Depths 215 O0 N O 2 3 290 4 275 200 Pins ana springs Classic Everest 29 A SCHLAGE PRIMUS PATENTED no nor pu NE Everest 29 Primus XP Everest Everest Primus DO NOT DUPLICATE PAT 5 715 717 DO NOT DUPLICATE 1 012 8558 6996 100 O3T Bottom pins Master pins Size Length Part no Size Length Part no O 165 34 300 2 030 34 202 1 180 34 301 3 045 34 203 2 195 34 302 4 060 34 204 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 34 306 8 120 34 208 7 270 34 307 9 135 34 209 8 285 34 308 9 300 34 309 n 14 Schlage Everest full size cylinder service manual Top pins Size Length Part no Application 235 34 101 Plug total 0 1 2 3 2 200 34 102 Plug total 4 5 6 3 165 34 103 Plug total 7 8 9 Cutting Everest 29 keys on the blue punch Cutting Everest 29 keys on the blue punch Handle Depth Bar Depth Number Red Knob Clamp Into Groove Between Ribs
16. horter angle has a lip to engage in the groove of the key section 4 Screwon the new red knob 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 Hex socket Lift up against spring Pressure while backing Screw out 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 n 4 Remove the lever spring washer and top jaw 5 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 will cut most frequently Tips for cutting Everest and Everest 29 keys Tips for cutting Everest and Everest 29 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 Push the die carriage all the way to the r
17. ight 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 arib 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 5124 C135 and 3135 have uny The position of the groove on C145 S145 grooves Be sure jaw engages into a C245 S245 C345 and S45 blanks groove requires loosening the knob and pushing the jaw toward the cutter to securely engage the groove Schlage Everest full size cylinder service manual 17 Everest key blanks Everest key blanks Operating keys 35 002 35 009 35 002 and T Standard for Standard D Family J Front for C ea De Family NAT all we ii 35 009 Back Optional for C Family Back 35 015 Optional Plain Bow for C and D Families 35 003 EAS 35 003 To order cut keys al CONTROL oa TS Change 35 prefix San 2 aS to 48 or 49 48 Change keys and random or stock cut keys 49 Factory master level key including control keys
18. inder service manual Larger key bow Everest Everest 29 XA A DO NOT DUPLICATE PAT 7 665 337 Uy Undercut groove keyway and Everest logo on plug face Everest Everest 29 t P Hole in cylinder shell for check pin Key control 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 newest patented Everest 29 families Both Everest and Everest 29 offer open keyways as well as families with restricted key control Open keyways Everest C Family Keyways are protected by U S utility patents 5 15 17 and 5 809 816 and Everest 29 S Family Keyways are protected by U S utility patents 7 665 337 against Unauthorized manufacture and distribution However the C Family and S Family keyways are readily available to the end user for fast and easy key duplication without any formalities All C and S keyways 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 and Everest 29 S keyways is to guarantee the end user genuine Schlage quality replacement keys and to provide commercial locksmiths and contract hardware dealers a group of keyways not available in home centers or retail key stands Everest 29 S Family keyways are the default keyways for all new Schlage
19. l SC GN 1001 for details on Everest 29 Primus XP cylinders A portion of the undercut groove is milled away on all conventional Everest and Everest 29 keys to prevent them from being altered to operate an Everest Primus XP or Everest 29 Primus XP cylinder N LC sr Lip to lift check pin C2 Lip removed to prevent Primus operation Everest full size cylinder service manual 5 Schlage Mechanical overview Mechanical overview Tumbler Cylinder cross section Springs Locked Unlocked Top pins Shell Master Pins Tailpiece as needed Bottom Pins amm 1 Plug Retainer Cap Check Pin Spring Retainer Cap Pin Check Pin Retainer Cap Pin Spring Traditional cylinder prior to July 2010 Traditional cylinder after July 2010 Everest Everest 29 Classic Everest Everest 29 and Primus and Primus Classic Traditional cams prior to April 2010 Modular cams introduced July 2010 Everest Everest 29 For cylinder housing sizes For cylinder housing sizes and Primus Classic 1 12 124 1V 1 128 1 4 1 2 3 4 1 8 3 8 5 8 Mortise cylinders use the Primus cam with one screw Modular cylinder cams may be Used with Classic Everest 29 and Primus key sections Use appropriate cam for cylinder housing size 6 Schlage Everest full size cylinder service manual Everest full size interchangeable core Everest full size interchangeable core
20. t crushed and cause a future lockout Additional keys will operate the cylinder Using the M504 548 follower for modular cylinders slide the flat section of the follower inside the shell and rotate the flat section until it comes under the bible All the master pins will then fall out Rotate the flat section until it is opposite the bible and slide follower until about an inch is protruding from the front 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 7 Ifyou are master keying leave the setup key in the plug Otherwise hold the check pin in position with your finger or thumb while removing the setup key and inserting the new operating key 8 Install the new pins in the plug 9 Orient the plug soit 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 1 Reinstall the cam tailpiece etc Schlage Everest full size cylinder service manual 13 Key bitting specifications Key bitting specifications The following specifications are the same for Schlage Classic keys including Primus XP Classic Code Card C45 for HPC 1200CM Code Machine Use of cutting wheel CW 14MC is not re
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