AL-Series Service Manual
Contents
1. Parts not compatible with cores manufactured before 1991 Important Use only graphite or similar material for cylinder lubrication Under no circumstance should any other type of material be introduced into the cylinder SCHLAGE September 1997 17 A SERVICE MANUAL LATCHES All AL Series latches have adjustable faceplates for flat or beveled doors except circular drive in latches Square Corner Latches Round Corner Latches Drive in Latches This kit adapts square corner latches and 10 001 strikes for 1 2 rabbeted door and frame preparations Latches and strikes not included Deadlatch Deadlatch Deadlatch Spacer for latch Shield for strike Springlatch Springlatch Springlatch 39 030 Rabbeted Latch and Strike Kit LATCHES Deadlatch Springlatch Housing Faceplate Description l 2 Throw Diameter I x 2 1 4 Square corner 11 085 11 068 2 3 8 I x 2 174 1 4 Radius round corner 088 Circular drive in non U L 11 104 I x 2 1 4 Square corner 1 1 8 x 2 1 4 Square corner standard e 3 4 3 4 1 8 x 2 1 4 Square corner 11203 11218 I Circular drive in non U L 11 105 11 11 __ Rabbeted latch and strike kit 39 030 SCHLAGE 18 September 1997 SERVICE MANUAL STRIKES ol Jo u 10 001 Square Corner Size 1 8 x 2 3 4 x 3 32 Lip Length 1178 Std 1 1 4 3 4 2 Includes C602. SCHLAGE September 1997 Test operation of lock to make sure you have followed instructions correctly INTERCHANGEABLE CORE How to remove core Insert control key and turn it clockwise 15 degrees until action stops Pull on key to remove core How to replace core Insert control key fully Push core into lever as far as it will go Turn key clockwise 15 degrees and push core completely into lever Turn key back to normal position and remove from core S 25 A SERVICE MANUAL INSTALLATION INSTRUCTIONS HOW TO ADJUST FOR NON STANDARD DOOR THICKNESS Remove outside lever a Non keyed locks except A40S See step 2 Place pointed end of spanner wrench into hole in lever Push in to depress catch and remove lever and driver b Keyed Locks Use screwdriver instead of key for A40S locks HINT It is easier to remove a keyed lever if the lock is positioned in the door cutout Insert key into cylinder Insert pointed end of spanner wrench or similar tool into hole in lever Turn key one quarter turn and push wrench to depress catch 7v Use tool to rotate castlenut bushing until screw post lines up with correct door thickness mark Adjust for door thickness Reverse Step 10 to reassemble levers Reassemble outside lever INTERCHANGEABLE CORE RETROFIT KIT INSTRUCTIONS Installation Tool Order Separately AL Series Kit a Interchangeable
3. AL85PD CHASSIS ASSEMBLY SEE PAGE 23 FOR INSTALLATION INSTRUCTIONS HOTEL MOTEL LOCK OUTSIDE LEVER FIXED ENTRANCE BY KEY ONLY PUSH BUTTON IN INSIDE EVER ACTIVATES VISUAL OCCUPANCY DICATOR ALLOWING ONLY EMERGENCY ASTERKEY TO OPERATE ROTATING SIDE LEVER OR CLOSING DOOR ELEASES VISUAL OCCUPANCY INDICATOR OTATION OF INSIDE SPANNER BUTTON ROVIDES LOCKOUT FEATURE BY KEEPING DICATOR THROWN SS E TRIM ASSEMBLY ASSEMBLED lt CHASSIS SCHLAGE 1 September 1997 9 A SERVICE MANUAL AL170 SINGLE DUMMY TRIM SINGLE DUMMY TRIM FOR ONE SIDE OF DOOR USED FOR DOOR PULL OR AS MATCHING INACTIVE TRIM Symbol Number Description 51 021 Lever amp Insert 700 009 Driver Lever 04 060 Rose 583 133 Sheet Metal Screw 8 x 2 Required 710 007 Spindle 4 Hub C604 400 Mounting Plote 50 Wosher A501 746 Thru Bolt 4501 16 7 Threaded Rod For Back to Mounting 3 gt ss IECH SCHLAGE 10 September 199 SERVICE MANUAL SYM NUM 5 BOL BER 023 DESCRIPTION LEVE amp INS ERT OPEN 021 LEVE amp INS ERT CLOSED 4 060 ROSE 020 CYL DER 5 0 2 2 BEN CYL DER INDICATOR 700 009 DRIVE LEVER A700 010
4. SCHLAGE September 1997 LUBRICATION AL Series lock mechanisms are designed for durability and seldom need servicing During assembly those points of contact which require lubrication for ease of operation are given an application of high quality petroleum based grease A touch of graphite is applied to the pin tumbler plug during assembly of the cylinder unit No further servicing should be required for an extended period except where locks are subjected to extremely heavy traffic Also if located 10 particularly dusty or dirty areas the grease may become contaminated resulting in a slow or otherwise unsatisfactory operation The case mechanism should then be cleaned in a noncorrosive petroleum solvent and relubricated Graphite only should be applied to the cylinder unit by blowing a small quanity into the keyway Note Precautionary measures according to solvent manufacturers instructions should always be followed TACTILE WARNING Tactile warning is achieved by milling three 3 grooves on the inside surface of the AL Series lever This 1s the means of identifying hazardous areas such as electrical closets and mechanical equipment for the visually impaired Tactile warning is available on all AL Series designs When ordering specify if both sides outside or inside levers require tactile warning Order by specifying design code 8JU Jupiter 8NE Neptune or 8SA Saturn 8SA Design 13 A SER
5. Core b Lever c Insert d Retainer e Driver Install Interchangeable Core 2 Driver and Retainer Place retainer and driver on end of installation tool as shown Be sure the flat sides of the retainer are aligned as shown Install the driver so the timing line is horizontal or parallel with the latch Insert installation tool into spindle and push in until it Remove Lever and Cylinder To remove existing lever from lock assembly insert pointed end of spanner wrench or small nail into hole in lever Exert pressure on wrench while turning key slowly until catch depresses and pull off lever e6 stops Remove installation tool a Press insert into back of the lever as shown Be sure the insert is firmly seated a Install Interchangeable Core Lever b Slide lever onto spindle up to catch Insert smooth end of installation tool through core opening in lever and turn tool until it engages the driver Turn installation tool clock wise and push lever on until it clicks into place Pull on lever to be sure catch is engaged Install Interchangeable Core With control key fully inserted push core into lever housing rotate key 15 clockwise and insert core completely Remove control key SCHLAGE September 1997 SERVICE MANUAL AL DOOR HANDING Schlage locks are reversible However the correct hand should be specified for all pin tumbler locks so th
6. For thru bolts on AL and D Series levers LONG BACKSETS Backsets 5 and over require extension links AL Series locks with long backsets are normally furnished with faceplates and 7 8 housings Links installed in latch holes require one G506 815 sleeve order separately to join latch and link Backsets over 5 require an additional 40 055 40 006 sleeve placed 1 8 from lock chassis Information Installation Kit Installation Kit on longer backsets is available upon request For A AL D and F Series Locks For A AL B D F H and Adjustable for 2 3 8 2 3 4 5200 5 locks Adjustable Extension Link and 5 backsets Removable for 2 3 8 and 2 3 4 backsets bushing adaptor for 7 8 latch Designed for special high speed hole The boring jig integrates hexagonal shank boring bits thru bolt hole locations for AL and equipped with an adaptor 9 and D Series levers For door to form an integrated unit for thickness 3 8 to 2 1 8 boring doors 5 16 to 15 16 thick 2 5 8 Backset Latch 5 Extension Link Sleeve 40 056 Boring Jig 40 012 Jig 40 015 7 8 Boring 40 016 7 8 Boring Bit REINFORCEMENT KIT 40 018 1 Boring Bit 40 019 1 Boring Bit The Schlage 57 001 reinforcement kit is to reinforce n 20 02 1 8 Boring Bit 4907023 121 8 Boring and help prevent the collapse of hollow metal doors 40 029 Strike Marking 40 026
7. PLUNGER amp BUTTON OUTSIDE A301 402 CA A501 615 WEDGE SPINDLE 604 273 COTTER PIN 00751 DE ROSE 6604 402 ROSE BLANK 0015 A501 874 PLATE HUB 00151 700 016 OUTSIDE 700 030 OUTSIDE 2 THICK DOORS A501 791 SPACER CAM 700 017 CA SPIRAL A501 PLUG CA 01 570 CA 501 90 PLATE HUB 00151 DE A700 003 SLEEVE SPINDLE ATI0 020 SP DLE amp CATCH OUTSIDE 700 032 OIII SPECIFY FINISH SCREW CHASSIS Saturn SAT A700 015 Standard Lever insert A700 034 Lever insert 2 doors SCHLAGE September 1997 SERVICE MANUAL FINISHES Schlage Lock finishes are durable top quality finishes obtained by the careful processing of solid brass bronze stainless steel or other materials Where required a protective clear coating is applied and cured under high temperature It is important that climatic conditions and usage be taken under consideration when selecting finishes This is especially true in areas subjected strong corrosive vapors humid climate or sea air which in a short time may have a damaging effect on metal finishes The longevity and preservation of the finish appearance is determined by bose m
8. DRIVE LEVER 2 THICK DOORS 10 01 SPR G CAGE INSIDE 70 012 SPR G CAGE OUTSIDE 0604 3554 CAST LE NUT 503 308 SPR 6 ANC HOR 700 007 HOUSING 700 005 HUB 700 028 HUB 2 THICK DOORS 700 014 HUB OUTSIDE 700 029 OUTSIDE 2 THICK DOORS 700 006 FRAME 700 004 PLATE OUTSIDE 70 001 SPINDLE amp CATCH OUTSIDE 710 004 SPINDLE amp CATCH INSIDE 501 305 PLAT E HUB INSIDE SO 99 e 919 SS 590 181 SLIDE NON RESTORING 590 180 SLIDE REST ORING 590 159 SLIDE NON RESTORING 590 158 SLIDE 85 901 311 SPRI 6 SLIDE A 508 597 SEAT SPRI 6 604 395 0 1446 SCREW 1 90 5 SPECIFY FINISH 1 037 ER GER amp BUTTON INSIDE SPECIFY DESIGN AND FINISH SCHLAGE September 1997 11 A SERVICE MANUAL DESIGNS Order by design code shown in parenthesis Jupiter JUP 12 SYMBOL NUMBER 51 038 DES CRIPTION PLUNGER amp BUTTON INSIDE 51 039 PLUNGER amp BUTTON INSIDE 51 040
9. Primus interchangeable core w o logo Insert 700 033 insert 2 doors 504 142 nstallation tool 5605 241 Retainer 01 054 Retrofit Kit SCHLAGE 16 September 199 Lever amp Insert 25 030 nterchangeable core w logo KS SS e 23 031 nterchangeable core w o logo 5 NS 51 022 Lever amp insert P L Core 700 008 Lever insert Standard Retainer 700 019 Driver See page 26 for retrofit kit instructions SERVICE MANUAL INTERCHANGEABLE CORE To remove interchangeable core insert control key and turn 15 to the right until action stops Pulling on key will extract core from the knob To install a new core insert control key and and push core into housing rotate key 15 to the right and insert core completely Rotate key back to original position and remove control key INTERCHANGEABLE CORE PARTS Symbol Number Description 34 101 thru 105 thru 3 Top pin 34 202 thru 209 2 thru 9 Master pin 34 300 thru 309 O thru 9 Bottom pin C503 1135 Tumbler spring C503 115 Retoiner cap spring C503 118 Retainer cap 55 058 Plug interchangeoble core 55 056 Control key blank 48 056 Control key cut B220 282 Interchangeoble core body w logo B220 283 Interchongeable core body w o logo C603 347 Retainer cap pin C603 956 Actuating ring C603 964 Actuating pin C603 967 Control pin A
10. cuts P Rod Sleeve Ward Ring Assembly Head 7 Transfer Knife Cylinder Body Loading Tool 40 16 compact precision tool for loading top pins and springs and for installation of ward rings into grooves of a warded cylinder plug Furnished with complete assembly instructions SCHLAGE September 1997 key gage to accurately Pin Tumbler Keys All Schlage locks come with two nickel silver keys as standard embossed with our company logo The nickel silver alloy from which all Schlage keys are made provides the base for accuracy in cutting and long cylinder wear Schlage will stamp DO NOT DUPLICATE across the bow of all versions of its keys at no extra charge when specified on orders Embossed Both Sides 35 100 5 Pin standard 35 101 6 Pin Stamped One Side 35 120 5 Pin 35 121 6 Pin 35 130 5 Pin 35 131 6 Pin Emergency Key AL40 Function 35 250 2 Large Bow 35 140 5 Pin 35 141 6 Pin EN Access Bow 35 143 5 Pin 35 144 6 Pin Available in C E F ond CE Only Hotel Emergency Key 35 102 6 Pin Spanner Key AL85 Function 35 25 21 A SERVICE MANUAL PLUNGER ASSEMBLY INSTRUCTIONS Outside Plunger Assembly Function 405 Disassemble Trim From Lock 2 Rotate inside rose counterclockwise to 1 Place a narrow tool into hole in inside lever remove from spring cage to depress catch Remove lever and driver Repeat for outside leve
11. ore specified 037 3 8 158 5 8 8 Hand of door Only one hand allowed EE Extended Equally 050 1 2 134 3 4 per line item Example RH Right Hand El Extended Inside 078 7 8 200 2 LH Left RR Right Reverse EO Extended Outside 100 I 400 4 LR Left Reverse ED Extended Differently 14 Enter detail for keying information 9 Latch Leave blank for standard or El or EO assumes the latch will be and for special requirements specify port number if non standard centered on a 3 4 thick door to latch is required LLL Less latch which material has been added ORDERING EXAMPLES Line ir Product E pana Additional Detail roduc an atc rike x im itional Details Item i Des Fin Des Fin Thk 50 AL53PD SAT 626 085 110 026 KEYED 000000 2 5 AL80RD 8SA 612 SAT 200 EE 138 KEYED KNURLED 0 5 LEVER 3 10 41405 JUP 609 625 1 068 10 001 W 41 005 EXT LINK 4 12 AL53LD NEP 605 LESS CYLINDER 5 12 20 720 606 NOTE Schlage order forms are ovailable at no charge by contacting your Schlage Representative or Customer Service SCHLAGE September 1997 EX A SERVICE MANUAL LIMITED WARRANTY Schlage Lock Company the Company warrants to the original purchaser that the products manufactured by it the to be free of defects in material and workmanship Provided i The Company has been notified within one year of purchase date and bee
12. 1 2 B Series when locksets are tightly mounted This kit should be Chisel Full Lip Bushing used with long backsets for installations in hollow 40 030 Strike Marking 40 028 1 2 Boring Bit metal doors to prevent lateral movement of latch bolt Chisel 40 029 Strike Mrk Chisel Specify door thickness 3 8 or 5 4 when ordering 40 031 Latch Marking 40 030 Strike Mrk Chisel Chisel AF H 40 031 Latch Mrk Chisel Reinforcement 501 565 3 8 doors lt gt A501 566 3 4 doors SS 40 032 Latch Marking 40 032 Latch Mrk Chisel Ei 40 035 40 036 40 050 40 057 5 16 Boring Bit M504 265 Jig Replacement M507 347 Socket Wrench Bushing SCHLAGE 20 September 1997 Sleeve d 501 567 Placement of reinforcements 37 001 in hollow metal door Reinforcement Kit SERVICE MANUAL KEYING Key Array Chart The Schlage Masterkey Department determines and makes the final decision in the selection and use of key sections Other keyways than shown below are available Allocation of other keyways is based on need and extent of the final system Priority is given to key systems that require a large number of cylinders and families of key sections to satisfy their keying requirements Contact your Schlage representative for availibility of other keyways Key Gage uer aee 10704 ps Order the Schlage VA RUE a measure the depth of key
13. 3 623 strike box 10 026 Full Lip Square Corner Size 5 8 x 2 1 4 x I 16 Lip Length 11 8 10 058 Circular Adjustable Size 3 4 Diameter Lip Length 7 32 SCHLAGE September 1997 10 004 1 4 Radius Round Corner Size 1 8 x 2 3 4 x 3 32 Lip Length 11 8 Includes 603 623 strike box 10 027 Full Lip 1 4 Radius Round Corner Size 5 8 x 2 1 4 x 1 16 Lip Length 1 8 10 025 Standard ANSI Prep 5 2 Size 1 4 x 4 7 8 x 3 32 Lip Length 3 16 Std 3 8 If required K510 066 strike box must be ordered separately g ee 10 042 Electric Strike Size 1 4 x 4 7 8 x 3 32 Voltoge 24VAC I2VDC Not designed for continuous duty ond electricol locking Optional Tamper Resistant Torx Screw Packs 205 311 4 Latch ond Strike Screws 48 52 x 1 2 T 15 2 Latch Screws 88 32 x 1 2 T 15 2 ANSI Strike Screws 12 24 x 1 2 T 20 203 312 Torx Tools 15 Torx Tool T 20 Torx Tool 19 A SERVICE MANUAL INSTALLATION TOOLS AND KITS Boring jigs and tools are designed to provide fast and accurate lock installation Complete kits contained in a heavy gage metal box or individual tools can be ordered for preparing doors and jambs for Schlage products 40 017 M504 271 40 080 Castlenut Wrench Catch Push Pin Drill Fixture
14. Door Reinforcements 20 Keys Key Array Chart Key Gage Cylinder Loading Tool 21 Plunger Assembly Instructions lt lt lt 22 23 Installation 0 5 24 26 Interchangeable Core Retrofit Kit Instructions 26 Ordering Procedures a ease Eeer eer iini d Limited Warranty ere 28 SCHLAGE September 1997 A SERVICE MANUAL ALIOS CHASSIS ASSEMBLY PASSAGE LOCK BOTH LEVERS ALWAYS UNLOCKED SCHLAGE 2 September 1997 SERVICE A MANUAL AL25D CHASSIS ASSEMBLY EXIT LOCK BLANK PLATE OUTSIDE INSIDE LEVER ALWAYS UNLOCKED SPECIFY DOOR THICKNESS 3 8 3 4 or 2 TRIM ASSEMBLY Ore em O To adjust for door thickness assemble blank rose to hub 69 by aligning appropriate hole A or B to hole C and install cotter pin Door Thickness 5 8 374 2 Requires regular parts assembled to order Hub In Assembled Chassis Blank Rose SCHLAGE September 1997 3 A SERVICE MANUAL 1405 BATH BEDROOM LOCK CHASSIS ASSEMBLY SEE PAGE 23 28 FOR INSTALLATION INSTRUCTIONS TURNING INSIDE LEVER OR CLOSING 2 DOOR RELEASES BUTTON PUSH BUTTON LOCKING CAN BE OPENED a O FROM OUTSIDE WITH SMALL SCREWDRIVER e N
15. INTERMOUNTAIN SCHLAGE AL Series Service Manual RE INGERSOLL RAND ARCHITECTURAL HARDWARE SERVICE MANUAL AL INTRODUC TION This manual contains a complete listing of parts and assemblies of AL Series locks manufactured by Schlage Lock Company beginning in 1995 Exploded views of each lock function are provided with an accompanying dot chart to identify parts for replacement purposes In addition this manual provides lock trim ordering procedures cylinders latches strikes and all auxiliary components of AL Series locks Orders for finished components should always show finish designation Orders for all Schlageg products must be placed through an authorized Schlage distributor or representative Schlage AL Series lock parts are manufactured 10 close tolerances and are interchangeable between functions using the same parts Conversion of functions is accomplished by identifying the parts necessary for substitution and following the assembly procedures as illustrated on the lock drawings For items not listed in this service manual contact Schlage Lock Company for availability or allowable substitutions Schlage Lock Company reserves the right to make changes in designs and specifications or to additions or improvements on its products without notice and without incurring any obligation to incorporate them on products previously manufactured The Schlage Lock Company is not responsible for any modi
16. ORTANT This lock is factory preset for 194 44mm doors See other side to center chassis in door or to change adjustment for other door thicknesses Place outside lock unit into position Make sure that latch prongs engage chassis housing and latch retracter engages latch bar Engage prongs Install inside rose 8 Align dimples on rose with grooves in spring cage Place rose against door and rotate clockwise until dimples snap into slots next to the grooves Install lever insert and driver 9 a Remove driver from lever and install it onto spindle b Assemble plastic insert into lever CAUTION Insert must be used for lock to function properly c Slide lever and insert onto spindle Push lever completely into place Pull on lever to make sure that catch is fully engaged ls 3 5 Driver Lever Install inside assembly 7 a Hold outside unit in place b Put spring cage into position on chassis c Place castlenut bushing on threads of chassis Hold outside lever in position while threading castlenut You will hear a ratcheting sound Continue tighten ing castlenut with tool until lock is fastened firmly d Insert and tighten mounting screws e Retighten castlenut with installation tool CAUTION When using power screwdriver for installation set to minimum torque setting fe nm
17. On Demand 888 321 3228 INGERSOLL RAND ARCHITECTURAL HARDWARE Form MS C71 Printed in USA Lock Division Schlage Lock Company Colorado Springs 1997 Ingersoll Rand Co
18. Plunger Assembly Functions ALAOS AL53PD and AL85PD Follow previous steps 1 thru 5 for disassembly 6 and chassis Insert new plunger bar less button assembly depress slide and push plunger To remove outside lever of keyed functions bar while releasing slide to hook into place insert key into cylinder Insert narrow tool into hole in lever Turn key 90 and depress catch with tool Pull off lever 8 Align plunger button assembly so lug fits into slot on spindle Position plunger button assembly onto bar and snap firmly into place 9 Reverse steps to reassemble complete lock and trim SCHLAGE September 1997 12 Install button assembly into spindle and snap firmly onto plunger bar When properly assembled rotating button will retract the slide 13 Reverse steps to reassemble chassis and lock trim Install spindle over bar rotate slightly and push into place Slot on spindle should be on same side as slide jaws 23 A SERVICE MANUAL INSTALLATION INSTRUCTIONS NOTE Accurate door preparation is essential for proper functioning of this lock Follow template and instructions carefully DOOR AND JAMB PREPARATION Mark door a Detach stub b Fold template at correct marking for door bevel high or low bevel or flat c Position template at correct height suggested height for centerline is 38 97mm from floor Mark center for lock hole Also mark for 2 holes fo
19. SEE PAGE 22 FOR INSTALLATION INSTRUCTIONS 26 SY ASSEMBLED lt CHASSIS 4 September 1997 SERVICE A MANUAL AL5OPD CHASSIS ASSEMBLY SEE PAGE 23 FOR INSTALLATION INSTRUCTIONS ENTRANCE LOCK PUSH BUTTON LOCKING PUSH BUTTON LOCKS OUTSIDE LEVER UNTIL UNLOCKED WITH KEY OR BY ROTATING INSIDE LEVER ASSEMBLED o September 1997 A SERVICE MANUAL AL53PD CHASSIS ASSEMBLY i SEE PAGE 23 FOR INSTALLATION ENTRANCE LOCK URN PUSH BUTTON LOCKING USHING AND TURNING BUTTON LOCKS UTSIDE LEVER REQUIRING USE OF KEY TIL BUTTON IS MANUALLY UNLOCKED USH BUTTON LOCKING USHING BUTTON LOCKS OUTSIDE EVER UNTIL UNLOCKED BY KEY R BY TURNING INSIDE LEVER or QO U TRIM ASSEMBLY ASSEMBLED 6 September 1997 SERVICE A MANUAL AL70PD CHASSIS ASSEMBLY CLASSROOM LOCK OUTSIDE LEVER LOCKED AND UNLOCKED KEY INSIDE LEVER ALWAYS UNLOCKED O c e ASSEMBLED September 1997 7 A SERVICE MANUAL AL80PD CHASSIS ASSEMBLY STOREROOM LOCK OUTSIDE LEVER FIXED ENTRANCE BY KEY ONLY INSIDE LEVER ALWAYS UNLOCKED amp TRIM ASSEMBLY E 0 N d SCH SCHLAGE 8 September 1997 SERVICE A MANUAL
20. VICE MANUAL CYLINDER UNITS AND PARTS Schlage locks are provided with cylinder units precision built to extremely close tolerances and the highest standards of accuracy Phosphor bronze springs nickel silver keys and pins are used throughout the Schlage offering The best combination of materials is used to ensure the manufacture of cylinders with ease of operation and long wear To order locks less cylinder units change product suffix letter P Example ALS3LD Primuso cylinders are available when key control and physical security are important concerns CYLINDER UNITS ME Cylinders High Security Controlled Access 8 21 020 6 Pin unit e JUP NEP SAT 21 021 Not Available T 21 020 Standard Cylinder CYLINDER PARTS Drawings are on page 15 Symbol Number X Description 55 006 Cylinder plug 6 pin 33 216 Cylinder plug indicator 6 pin 34 101 thru 103 thru 3 Top pin 34 202 thru 209 2 thru 9 Master pin 34 300 thru 309 0 thru 9 Bottom pin A201 849 Body 6 pin 700 031 Bor 6 driver for 21 020 A700 023 Bar for 21 02 503 13 Tumbler spring Retainer cop pin Retainer cop Driver for 21 021 Obstruction pin for 21 021 ndicator pin spring for 21 021 20 528 C604 37l ndicator pin for 21 021 Primus High Security U L 437 Listed 21 021 Hotel Function Indicator Cylinder Important Use only graphite or simi
21. at they may be assembled assure key cuts are in the upright position Hand information is also necessary ensure proper finish of latchbolt and strike for locks ordered that are to be installed on reverse bevel doors Follow the diagram to correctly determine the hand of the door A LH Left Hand RH Right Hond i Ke Left Hand Reverse 4 RR Right Hand Reverse ORDERING PROCEDURES To order Schlage products descriptive data should be in the same sequence 05 shown Outside Fin Inside Fin Product Additional Details Des Des Line item number Strike Leave blank for standard or I5 Enter dimension for non standard strike 2 Quantity specify part number if non standord lip length and mortise cylinder or 3 Complete lock product or part number strike is required LLL Less Strike blocking ring length 4 Outside design code 1 Door Thickness Enter door thickness Example 5 Outside finish code if non standard Example 158 3 8 012 1 8 18 11 8 6 Inside design code Leave blank if 2147 2 1 4 2l2 2 1 2 018 3 16 114 11 4 same as outside design code 2 Extension 025 1 4 138 3 8 7 Inside finish code Leave blank if Enter one of the following when doors 031 5 16 2 11 2 same as outside finish code 2 thick or greoter
22. es do not allow limitations on incidental consequential damages or how long an implied warranty lasts so that the above limitations may not fully apply 2 This warranty gives specific legal rights and a buyer may also have other rights which may vary from state to state For warranty service and shipping instructions contact the Schlage Lock Company Customer Service Department 2401 Bayshore Boulevard San Francisco California 94134 800 847 1864 The Schlage Lock Company reserves the right to make changes in designs and specifications or to make additions or improvements on its products without notice and without incurring any obligation to incorporate them on products previously manufactured The Schlage Lock Company is not responsible for any modification addition or alteration to our products by others SCHLAGE 28 September 199 SERVICE MANUAL AL NOTES September 1997 29 Administrative Offices 1915 Jamboree Drive Suite 165 Colorado Springs 80920 719 264 5300 719 264 5382 Commercial Customer Service 2401 Bayshore Boulevard San Francisco CA 94134 P O Box 193324 San Francisco CA 94119 800 847 1864 FAX 800 452 0663 FAX 415 330 5627 Order Processing FAX 800 452 0665 International Division Ingersoll Rand Architectural Hardware 1076 Lakeshore Road East Mississauga Ontario L5E 1E4 Canada 905 278 6128 FAX 905 278 1413 Internet http www schagelock com Fax
23. etal and finishing process Clear protective coating or other organic finishing applications may require different methods of cleaning and care As an example non clear coated finishes should not be cleaned with 50005 or any solvents organically coated surfaces should periodically be cleaned with a mild non abrasive soap ond buffed lightly with a clean cloth The type of base metal and finishing techniques must be considered when applying any cleaning or preservative method Contact the Schlage Technical Services Department for further information on the care of finished hardware n some instances for customer convenience the most appropriate BHMA finish symbols are used to indicate similarity of appearance regardless of base metal or finishing process AL Series levers are zinc based material and are plated to match finishes indicated Finish numbers in the 600 Series are the BHMA Builders Hardware Manufacturers Association industry standard The nearest old U S equivalent code designations are shown in parenthesis Symbol Description o BRIGHT BRASS 605 5 Clear Coated SATIN BRASS 606 4 Cleor Cooted SATIN BRASS BLACKENED Satin 609 5 Relieved Clear Coated SATIN BRONZE 6l2 10 Clear Coated OIL RUBBED BRONZE Oxidized Satin Bronze Oil Rubbed No Coating BRIGHT CHROMIUM PLATED No Coating SATIN CHROMIUM PLATED No Coating 613 108 625 26 626 26D
24. fication addition or alteration 10 our product by others Schlage Lock Company 2401 Bayshore Boulevard San Francisco CA 94134 800 847 1864 Fax 800 452 0665 http www schlagelock com Printed in U S A CERTIFICATIONS ANSI BHMA A156 2 1996 Series 4000 Grade 2 All functions U L listed for 3 hour doors DOOR RANGE 5 8 to 7 8 Standard 7 8 to 2 Regular parts assembled 10 order METRIC CONVERSION CHART All dimensions shown in this service manual are in inches use the To convert to millimeters metric conversion chart shown below September 997 SERVICE MANUAL TABLE OF CONTENTS Assemblies Description Page AL10S Passage tee 2 AL25D Exit Sse ursus 405 Bath Bedroom Privacy Lock 4 Entrance Office Lock 5 AL53PD Entrance LOCK 6 AL70PD Classroom eve cene eme 7 AL80PD Storeroom 8 AL85PD Hotel Motel Lock 9 AL170 Laut 10 Ports ee ee EE E Ee RE EE 2 Finishes Lubrication Tactile Warning rrr cree 13 Cylinder Units and 14 15 Interchangeable Cores Design and 6T Eaten EES 18 Sin KGS LE LLL Bee 9 Installation Tools Backset Links
25. lar material for cylinder lubrication Under no circumstance should any other type of material be introduced into the cylinder 20 728 Primus Controlled Access SCHLAGE 14 September 1997 SERVICE A ANUAL DER STANDARD CYLIN HOTEL FUNCTION INDICATOR CYLINDER A SERVICE MANUAL INTERCHANGEABLE CORES DESIGN AND PARTS Available in Saturn design for all AL Series keyed functions except Hotel Motel function AL85 as complete locks or in retrofit kits Existing installations can be retrofit without removing lock from door To order locks with interchangeable cores change product suffix letter P to R Example AL53RD To order locks less interchangable cores change product suffix letter P to J Example AL53JD Primuso cores are available when key control and physical security are important concerns INTERCHANGEABLE CORES 23 030 23 031 20 740 20 741 Interchangeable Core w logo Interchangeable Core w o logo Primus Interchangeable Core Primus Interchangeable Core w logo Controlled Access logo Controlled Access INTERCHANGEABLE CORE DESIGN S gt Saturn M504 142 Installation Tool Order as needed per project INTERCHANGEABLE CORE ACCESSORY AND SERVICE PARTS Description 01 025 Lever amp insert driver and retainer 01 054 Lever amp insert core driver and retainer 01 126 Driver and retainer 20 740 Primus interchangeable core w logo Driver 20 741
26. n given the opportunity of inspection by return of any alleged defective Product to the Company or its authorized distributor at the address specified herein free and clear of all liens and encumbrances transportation prepaid accompanied by the statement of defects and proof of purchase and ii The Product has not been modified abused misused or improperly installed maintained and or repaired during such period and iii Such defect hos not been caused by corrosion or ordinary wear and tear E COMPANY MAKES NO OTHER WARRANTY AND A MPLIED WA TIES CLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR RPOSE ARE LIMITED TO THE DURATION OF THE EXPRESSED WAR TY PERIOD SET FORTH ABOVE E COMPANY S MAXIMUM LIA Y HEREUNDER IS LI ED TO THE PURCHASE E OF THE PRODUCT IN NO EVENT SHALL THE COMPANY BE LIABLE FOR ANY EQU IAL INDIRECT INCIDENTAL OR SPECIAL DAMAGES OF ANY NATURE SING FROM THE SALE OR US HIS PRODUCT WHETHER IN CONTRACT RT STRICT LIABILITY OR OTHERWISE NOTE Should the Product be considered a consumer product as may be covered by the Magnusson Moss Federal Warranty Act please be advised that I Some stat
27. r mounting screws d Use stub to mark center of door thickness HINT For retrofitting existing lock holes fold template in half to locate position for the 2 mounting screws Door bevel Drill 4 holes a Drill a 278 54mm hole through door from both sides to avoid damaging door b Drill 2 546 8mm holes for mounting screws Drill 1 25mm 78 22mm depending on latch housing diameter in door edge Install latch 3 a Insert latch into hole Trace around faceplate b Chisel out wood until faceplate fits flat with door edge c Fasten latch to door so that beveled side of latchbolt faces jamb 24 Install strike a Mark vertical line and heightline on jamb exactly opposite center of latch hole b Drill 2 1 25mm holes 34 19mm deep Sie 8mm above and below heightline 1 25mm Hole 34 19mm deep 8mm 54e 8mm 6 Use strike plate to pattern for cutout Clean out hole and install strike LOCK INSTALLATION Disassemble inside trim a Insert pointed end of spanner wrench into hole in inside lever Push to depress catch and remove lever Also remove driver b Unscrew and remove castlenut bushing Use metal tool or plastic tool provided c Remove spring cage SCHLAGE September 1997 SERVICE MANUAL INSTALLATION INSTRUCTIONS Install outside lock unit 6 IMP
28. r and driver Disassemble Chassis 5 Depress slide unhook and remove inside 4 Remove chassis screws Straighten lugs and plunger and spindle remove housing from chassis If necessary rap on edge of housing to loosen assembly 7 Remove slide and springs 8 Remove cam from outside spindle ee Using provided wrench unscrew inside and outside castlenut bushings Using Phillips screw driver unscrew through bolts Remove inside spring cage anchor spring and outside rose and spring cage assembly Hold palms of hands around lock to prevent springs from escaping from slide Press forward with thumbs against frame tabs while pushing upward with index finger to disengage hub plate 9 Use pliers to snap off outside button from plunger bar Now remove the plunger bar SCHLAGE September 1997 SERVICE MANUAL Outside Plunger Assembly Function 405 10 To remove outside spindle depress catch Outside Button and Bar Assembly and push slide into hub and frame as far as it 11 Insert outside spindle through lock frame from will go Rotate spindle until catch aligns with inside of frame Insert plunger bar less button slot in hub and plate Depress catch again assembly into spindle as shown The bar will Remove spindle stop against the catch in the spindle Insert cam into spindle The bar will become trapped in the spindle by the cam Reposition hub plate slide and springs in frame Inside
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