Kaba 5402 Series, 5401 Series, 5400 Series, 5140 Series, 5900 Series Technical Manual

...

Technical Manual

Table of Contents

SECTION 1 – INTRODUCTION

Peaks Global Brochure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Kaba Access Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Terminology Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Competitive Patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Key Blank Identification Number and Peaks Global Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

Kaba Peaks Global Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

SECTION 2 – PRODUCT INFORMATION

Conventional Mortise Cylinders – 5401 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Mortise Cylinder Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Conventional Rim Cylinders – 5402 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Key-in-Knob Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Key-in-Knob Cylinders – 5400 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

Padlocks – Key-in-Knob Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21

Padlocks – Interchangeable Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Cabinet Locks and Specialty Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

Small Format Interchangeable Cores (Capped) – 5800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23

Small Format Interchangeable Cores (Spring Loaded) – 5900 Series . . . . . . . . . . . . . . . . . . . . . . . .2-23

Large Format Interchangeable Cores for Corbin Russwin – 5140 Series . . . . . . . . . . . . . . . . . . . . .2-23

Large Format Interchangeable Cores for Yale – 5240 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Large Format Interchangeable Cores for Medeco 32 – 5340 Series . . . . . . . . . . . . . . . . . . . . . . . . .2-24

Removable Cores for Schlage – 5440 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Removable Cores for Sargent – 5540 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25

Product Specifications and Testing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26

SECTION 3 – KEY CUTTING AND PINNING

Lubricating the Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Determining Node and Disc Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Installing blocking Pins, Discs and Fillers – Conventional Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Installing blocking Pins, Discs and Fillers – Interchangeable Cores . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Inserting Peaks Patented Bottom Pins in Small Format Interchangeable Cores . . . . . . . . . . . . . . . . .3-4

Cylinder Stamping, Marking, Lubrication & Tailpiece Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Key Bitting Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Cutting Keys by Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Duplication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Components for Pinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Pin Lengths and Stack Heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Pinning Conventional Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Pinning Interchangeable Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Calculating Small Format Interchangeable Cores – A2 System Pin Stacks . . . . . . . . . . . . . . . . . . . .3-17

Calculating Other A2 Pinning Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18

A2 System Small Format Interchangeable Core Pinning Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

Calculating Small Format Interchangeable Cores A4 Pinning Stacks . . . . . . . . . . . . . . . . . . . . . . . .3-20

Calculating Other A4 Pinning Stacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

A4 System Small Format Interchangeable Cores Pinning chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

SECTION 4 – KEY CONTROL AND RECORD KEEPING

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Authorized Signature Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Dealer Systems – Authorized Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Adding / Deleting Names on the Signature Card for Factory Key Systems . . . . . . . . . . . . . . . . . . . . .4-2

Authorized Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Writing the Key System Expansion Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

The Standard Key Coding System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Special Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

SKD Combinations – Non-master Keyed Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Designing Top Master Keys and Control Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

The TMK Register . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

SECTION 5 – CYLINDER INSTALLATION GUIDE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Identifying the Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Cylinder Removal Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Arrow Architectural Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Corbin Russwin Architectural Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Corbin Russwin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Falcon Lock Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Marks USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

Sargent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Schlage Lock Co. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Yale Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

A publication of Kaba Access Control 2941 Indiana Ave. Winston-Salem, NC 27105

No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without prior written permission from the Publisher.

The information contained in this publication is accurate to the best of Kaba Access Control’s knowledge.

Specifications are subject to change without notice.

PEAKS GLOBAL TECHNICAL MANUAL

Peaks Global®Advantages

• Blanks and cut keys protected by strong, uncontested utility patents

• Patented key control without added expense of UL437

• Retrofits a wide variety of lock brands

• Combines conventional mortise, rim and key-in-knob cylinders, with Best, Arrow, and Falcon interchangeable cores, and Corbin Russwin, Medeco, Yale, Schlage and Sargent removable cores, all in the same patent protected keying system

• Maximizes use of existing hardware for substantial cost savings

• Cores can be added to existing non-IC systems without loss of keying capacity

• Cylinders resistant to key manipulation for safer master keying

• Lowest cost entry into key control market

• Technically simple

• Uses existing key machines

• Distributor supported

• Made in America by world's oldest, largest manufacturer of key control and high security products

• World class factory support

Technical Manual Section 1: Introduction

Introduction to Peaks Global

Peaks®Global – Providing Dealers with an exclusively unique

patented keyway.

Kaba has produced high security key control products for over 25 years. From the strength of that technology comes a new system – Peaks Global. Peaks Global is a dealer exclusive patented key control system available in a limited number of keyways. It allows each Dealer to have a unique keyway so exclusive that there isn’t another one like it, anywhere on the globe.

Introduction

For dealers lucky enough to get one of the Global Exclusive keyways, this means something to call your own. You are the only one who can sell systems based on your keyway. You can even customize the key bow to include your logo and name.

Peaks Global gives you complete control over sales and service of your keyway, and virtually guarantees repeat business from existing customers. It feels good to be the expert – to be in control of a product, and Peaks Global is the product to give you that control.

The advantages of Peaks Patented Key Controls

To create Peaks Global, Kaba engineers first utilized the technology made popular by our original Peaks system. Machined nodes were then added to the side of the key for added protection against unauthorized duplication. This utility-patented design provides more security than common design

patents. Your authorization is required to order cut keys, key blanks, and key cylinders, which provides you with complete control – and you and your customers with actual security – not simply the words “Do Not Duplicate.” The Peaks Global design eliminates vector forces from users overtorquing keys and using them to turn latches – ensuring trouble free service.

Peaks Global does not require any special training to cut the keys, and utilizes standard Peaks key cutting equipment.

Section 1 - 1

US Patent # 6,983,630

Peaks Global Operation

Fillers: Placed where there are not active Discs

Blocking Pins:

Stops unauthorized keys

Nodes:

Strong, machined protrusions on both sides of the key – in proper code patterns, moves active disc to provide proper shear line

Peaks Global Compatibility

Discs: Placed according to your specific

node pattern on side of keyway

Plug

Peaks

Security

ocking Technologies

Peaks Global offers the added security of three locking technologies and shear lines

Pins – engaged by cut of key Peaks Technology – engaged by

peaks on top and bottom of key Disc Technology – engaged by nodes

n side of key

These three technologies work together during operation of the product to make Peaks Global truly unique in its function – a claim backed up with our patents. Unique function and an exclusive keyway combine to create a revolution in patented key control.

Peaks Global

Rim

Mortise

Interchangeable Cores

Key in Lever / Knob

The Peaks Global key also works in conjunction with interchangeable and removable cores for installations requiring a mix of cylinder formats.

The most adaptable Patented Key Control System

Peaks Global provides a flexible system that can be master keyed. Kaba Peaks products are the industry leader in compatibility with all major hardware brands. No matter what hardware is used at a facility, you can use one Peaks Global key to operate all the locks. This allows customers to upgrade to high security by replacing only the cylinder, not the hardware.

The Peaks Global system is designed to provide dealers an exclusive keyway for conventional cylinders. This design includes retrofit cylinders for ANSI mortise, rim, deadbolt, padlock, and key-inknob / lever designs.

Introduction

Replacement Cylinders Fit: Adams Rite, Alarm Lock, American Lock, Arrow, Best, Corbin, Detex, Dor-o-matic,

Falcon, Jackson Device, Locknetics, LSDA, Marks, Master Padlock, Medeco, Monarch, Olympus, Omnia, PDQ, Precision, Russwin, S. Parker, Sargent, Schlage, Simplex, Unican, Von Duprin, Yale and many more.

Section 1 - 2

Kaba Access Control

Kaba has provided strong, powerful security solutions since 1862, when German businessman Franz Bauer established a locksmith and safe company named Kassa Bauer (Bauer Safe). Over the past 140 years Kaba has continually increased its capabilities and expanded its vision, becoming a world leader in access control solutions and door hardware.

Today, Kaba’s worldwide operations serve millions of customers in more than 150 countries with a comprehensive set of products and services that range from safe locks to access control system integration. More than 7,000 Kaba employees, located in 20 countries are working to maintain the highest levels of customer satisfaction as we continue to grow and expand our vision.

Kaba defines the future of access control as Total Access – the integration of all access control devices, from door hardware to mechanical locking systems, to electronic access systems and data collection. The people of Kaba are committed to leading the access control industry.

Terminology Used in This Manual

Professional industry groups, like the Associated Locksmiths of America (ALOA), the Builders Hardware Manufacturers Association (BHMA), and the Door and Hardware Institute (DHI), work to standardize terminology. This manual conforms to the ALOA publication, The Professional Glossary of Terms Related to Cylinders, Keys and Master Keying, hereinafter referred to as the Glossary. It also conforms to the keying symbols of the DHI Keying Manual and BHMA standards. The symbols of the Standard Key Coding System are the industry standard accepted by all lock manufacturers.

Resources

Kaba recommends the following resources:

1. Door and Hardware Institute publications, available from DHI, 14170 Newbrook Drive, Chantilly, VA, 22021. Tel: 703-222-2010

- Abbreviations and Symbols as used in Architectural Door and Hardware Schedules and Specifications

- Sequence and Format for the Hardware Schedule

- Basic Architectural Hardware

- Keying Manual

2. ALOA publication, available from Associated Locksmiths of America, 3003 Live Oak Street, Dallas, TX 75204. Tel: 214-827-1701

- Fundamentals of Master Keying

Certain forms used in this manual have been reprinted with permission from Fundamentals of Master Keying. You are free to copy the master keying forms at the back of the manual as is, or alter them. There are many

Introduction

other forms available, from site surveys to specialized bitting lists.

3. Kaba Customer Service and Key Records Department are available from Monday through Friday, 7:30 a.m.

to 4:30 p.m. Eastern Time to answer questions. For Customer Service please call 1-800-849-8324, Ext. 1.

For the Key Records Department, please call 1-800-849-8324, Ext. 285.

Peaks Key Control Systems are the most cost effective, patented high security key control systems available. The Kaba Peaks Global high security cylinder family retrofits most Grade 1 and Grade 2 hardware

sold in the US today. Available in key-in-knob, mortise, rim, and interchangeable core configurations. Kaba Peaks Global provides the unique ability to key Peaks Global standard cylinders and Peaks Classic interchangeable core cylinders alike so one Global key will operate both styles of hardware. A series of discs located along both sides of the plug prevent unauthorized keys from operating the cylinder. Special nodes on the key interact with the discs within the plug that are required for proper cylinder operation. Since the uncut key blank itself is patented, Kaba controls blank manufacture and distribution.

Section 1 - 3

Patents

The primary purpose of patented high security locks is the prevention of unauthorized key duplication. Contracts, factory marked blanks, limited distribution, key records controls, and strong utility patents are essential to stateof-the-art key control.

Fabrication of Peaks Global key blanks by anyone other than Kaba is an infringement of utility patents.

Patent Criteria: A novel mechanical feature on the uncut blank, without which the lock will not operate, is the critical mechanical requirement for a utility patent to protect against unauthorized key duplication.

The patent number for Peaks Global is 6,983,630.

Kaba Access Control and Kaba Holding AG will bring legal action against any person or persons producing or contributing to the production of unauthorized Peaks Global keys or key blanks.

Competitive Patents

Brand Patent Type Expires

Kaba’s Peaks Global utility 2023

Assa CLIQ utility 2021 Medeco M3 utility 2021

Kaba L10 utility 2017

Corbin Pyramid utility 2017 Assa Twin Pro utility 2015 Schlage Everest utility July 2014 Arrow Flex Core utility July 2012 Sargent Signature utility Dec 2012

Kaba Gemini T utility Aug 2012

Medeco Keymark utility Jan 2011

Kaba’s Peaks Classic utility June 2010

Assa Twin V-10 utility Nov 2008

Kaba Gemini utility April 2006

Schlage Primus utility July 2005 Medeco Biaxial utility expired 2004 Assa Twin 6000 Blank design expired 2000 Abloy DiskLock Pro utility expired 1999 Medeco Original utility expired 1987 Distributor “locksmith” keyways none not patented Commonly called “restricted” keyways none not patented

Introduction

Section 1 - 4

Key Blank Identification Number and Peaks Global Contracts

ll Peaks Global key blanks are marked with a unique identification number. The Kaba key control contract and

A this manual specify certain key control procedures. Breach of contract or failure to abide by factory key records policies can result in loss of the product line.

Contracts specify that:

1) The blank ID number may not be removed, stamped-over, or altered in any way;

2) Parties under contract may not duplicate any keys without following proper key records

authorization procedures;

3) Key blanks may not be sold, lent, or given away;

4) Proper key records must be kept and authorization forms maintained.

Kaba Peaks Global Quality

Kaba Access Control employs the latest machining techniques to ensure smooth reliable operation throughout a wide variety of cylinders to provide hardware to fit the full spectrum of security needs. Kaba uses high quality brass to manufacture the plug and shell of each cylinder. All Kaba Peaks keys are made of nickel silver which incorporates a large bow capable of receiving stampings and use by physically impaired people. All Kaba Peaks family of reliable cylinders are designed and manufactured to stand up to the heaviest of use over an extended life of many years.

The patented security features of Kaba’s Peaks Global Security Cylinders provide new capabilities to the standard pin tumbler lock design without complicating the procedures involved in servicing the cylinder. Patent protected Kaba Peaks keys use standard pin tumbler combination bittings, so standard code and duplicating key machines can cut Peaks Global keys from key blanks that are produced with the node patterns from the factory.

Introduction

Section 1 - 5

Technical Manual Section 2: Product Information

Conventional Mortise Cylinders - 5401 Series

6-pin 140

Cylinder length measured from

nder the head

u to back of the cam. Example shown is 1

ylinder.

/4"

onventional mortise cylinders are

C available in 1

/8" and 11/4" lengths.

Longer length applications can normally be handled by using small format interchangeable core housings.

Collars are not included. Please order

collars separately.

Cams for conventional mortise cylinders are attached with 4701-98-4118 Loctite®coated screws. One 3418-00-2000 cam cover is placed over the cam before screws are installed.

If cams are changed in the field, use new screws and tighten them firmly.

Please specify cam when ordering. Contact Kaba about other cam requirements. See bottom of this page for mortise cylinder kit.

Cams shown below are not for small format interchangeable core housings.

3418-00-3000 3418-00-3001 3418-00-3002 3418-00-3003 Corbin Russwin Adams Rite Standard Best and DL4000 Corbin Russwin length: 1.080" cloverleaf

3418-00-3004 3418-00-3008 3418-00-3009 3418-00-3010 Sargent and Yale AR 4070 Schlage L Falcon length: 1.010"

Mortise Cylinder Kits

Product Information

mortise cylinder kit, 140 6-pin 1

5401-xx-1038 uncombinated xx = Finish

/8"

Kit includes: standard, Adams Rite, cloverleaf, Sargent / Yale and Schlage L cams,5/32" spacer, spare Loctite®coated screws and a cam cover.

Section 2 - 1

Conventional Rim Cylinders - 5402 Series

6-pin 140

5402-xx-1010

tandard

s screw hole locations

5402-xx-1012 screw holes "high and outside" for Sargent exit devices

Each 5402 cylinder assembly includes these components:

4701-98-4118

screws, 2 required

plug & shell assembly

4702-80-2009

rim cylinder tailpiece

3410-00-2001

tailpiece retainer

3500-xx-2003 collar finish to match cylinder

backplate

break-off screws 2 required

Product Information

Section 2 - 2

Key-In-Knob Cylinders

Key-in-knob cylinder kit

Universal cylinder kit for cylindrical and tubular locks ("99" kit)

400-xx-1099 uncombinated

5 xx = Finish

The screw cap plug retainer accepts original tailpiece and driver assemblies by Arrow, Baldwin, Corbin Russwin, Falcon, LSDA, Sargent, Schlage and others. Kit includes a cylinder assembly and one each of the components shown:

single cylinder lost motion tailpiece

3450-80-2004 timing washer

The Universal "99" cylinder kit can be used with the following lock types. For details, please refer to the specific line drawing of the product.

Manufacturer Lock Type Model # Manufacturer Lock Type Model #

Amerock See Arrow Arrow H, L, S and W series -09 Arrow M and Q series levers -09 Arrow M series Ball knobs -20 Arrow Single Cyl. Deadlocks -90 Arrow Double Cyl. Deadlocks -92

Cal-Royal BA grade 2 knobs -14 Cal-Royal CGN grade 1 levers -18 Cal-Royal SL grade 2 levers -18 Corbin Russwin CL3800 -01 Corbin Russwin CL3300 -20 Corbin Russwin CL3400 and CL3600 -11 Corbin Russwin ED8000-A5 / N5 lever trim -11

Falcon X series Hana knobs -33 Falcon X series knobs, except Hana -12 Falcon B series grade 2 levers -18 Falcon F series levers -17

Product Information

Falcon N series knobs -17 Falcon LY grade 1 levers -23 Falcon RU grade 1 unit locks -01 Falcon S series knobs, except Hana -13 Falcon S series Hana knobs -33 Falcon T series levers -01

Kaba 1411 padlocks -41 LSDA LS100B, 100P, 100T knobs -14 LSDA LX1000 grade 1 levers (1994) -18 LSDA LX1000 grade 1 levers (1998) -18 LSDA LH1000 grade 1 knobs -17 LSDA L100 grade 2 levers -18 LSDA 600 series clutch levers -18 LSDA Single cyl. deadlocks -90 LSDA Double cyl. deadlocks -01 Marks 110, 120 series -14

3450-00-2001

short double cylinder

lost motion tailpiece

3450-00-2000

3450-80-2003

spacing washer

3450-00-2002 long double cylinder lost motion tailpiece

Marks 130 series deadlocks -01 Marks 170, 190, 195 series levers -01 Marks 210 series knobs -01 Master ProSeries padlocks -01 New Standard Brass padlocks -41

Omnilock Knob, key by-pass -17 Omnilock Lever, key by-pass -18 PDQ SK, SP, ST levers -16 PDQ SV grade 2 -84 PDQ Imported grade 1 levers -23 Sargent 5500 Line grade 2 knobs -14 Sargent 465, 485, 486 single cyl.

Sargent 464, 484 double cyl.

Schlage A series, non-Orbit knobs -14 Schlage A series, Orbit knobs -07 Schlage AL series levers -20 Schlage B single cyl. deadlocks -90 Schlage B600, 700, 800

Schlage B double cyl. deadlocks -92 Schlage B600, 700, 800

Schlage C & D series grade 1 knobs -17 Schlage C & D series grade 1 levers -18 Schlage S series grade 2 levers -01 Schlage PL series padlocks -01 Schlage Old style 45-101 padlocks -01

Select/Medeco 2000/All-N-One deadlocks -01 Trilogy 2500 by-pass, knob -17 Trilogy 2500 by-pass lever -18 Ultra 7000 Ball knob -18 Von Duprin 22 series exit knob trim -07

patented

SD/3A

1590-80-2000

deadlocks -90

deadlocks -92

single cyl. deadlocks -91

double cyl. deadlocks -93

6-pin 140

Large diameter

plug requires

J or K series

bottom pins and

6140-00-3004

patent bottom pin.

S/3C

4700-80-2002

SA/3B

4700-80-2001

Section 2 - 3

Key-In-Knob Cylinders

he 5400-xx-1095 cylinder kit with small diameter plug face ("95" kit)

5400-xx-1095 uncombinated xx = Finish

patented

Falcon applications require Falcon tailpiece kit, Kaba part number

700-00-5109. Falcon, Cal-Royal, LSDA, and Weiser deadlocks

4 require OEM tailpieces.

The "95" cylinder kit is used for selected applications which require a small diameter plug face. The "95" kit includes a cylinder assembly and one each of the components shown:

3450-00-2000

3450-00-2002

long double cylinder

lost motion tailpiece

3450-80-2004 timing washer

single cylinder lost motion tailpiece

3450-00-2001

short double cylinder

lost motion tailpiece

The "95" cylinder kit can be used to make the following. For details, please refer to the specific line drawing of the product.

Manufacturer Lock Type Model # Manufacturer Lock Type Model #

Cal-Royal LSD single cyl. deadlock -01 Cal-Royal LSDD double cyl. deadlock -01 Falcon D series deadlocks -01 Falcon X series knobs/unit locks -21 Sargent 6 Line knobs, except Ball -10

Sargent 2000 exit device trim -10 Sargent 6500 Line -10 Weiser D 9370/9470 series deadlocks -01 Yale 5300L grade 2 levers -95 Yale 5300LN grade 2 levers -56

Sargent 10 Line levers -10

3450-80-2003

spacing washer

SD/3A

1590-80-2000

Large diameter

plug requires

J or K series

bottom pins and

6140-00-3004

patent bottom pin.

S/3C

4700-80-2002

SA/3B

4700-80-2001

The 5400-xx-1006 for Arrow - LSDA - Schlage key-in-knob cylinders ("06" kit)

5400-xx-1006 uncombinated xx = Finish

The "06" cylinder also accepts original Arrow, Ilco, Lori, Marks and Sargent fixed tailpieces.

The "06" cylinder kit includes a cylinder assembly and one each of the components shown:

SD/3A

1590-80-2000

SA/3B

4700-80-2001

The "06" cylinder kit can be used for the following lock types. For details, please refer to the specific line drawing of the product.

Manufacturer Lock Type Model # Manufacturer Lock Type Model #

American 3600 and 3700 series padlocks -01 Trilogy 2700 and 3000 levers -03 Arrow M series Tudor and Darrin -26 Master System 29 padlocks -01

S/3C

4700-80-2002

3400-00-2009 security bushing

"06" plug & shell

side view note bevel

Section 2 - 4

Product Information

Tools

3800-00-4050 Peaks Multi-Gage checks .140" and .150" spacing and depth for the A2 and A4 system. Peaks Global cylinders are not available in .150" spacing.

6840-00-3540 staking fixture

3400-00-4000 staking fixture for conventionals

3400-00-4001 or 6440-00-4001 staking tool

3840-00-3540 140 capping block (6 holes)

3800-00-3547 capping tool is used with both capping blocks

6 4 4 0 - 0 0 - 3 5 4 0 staking fixture

3800-00-3548 ejector tool

Product Information

Universal A2 3400-00-5012 Universal A4 3400-00-5004 Schlage RC 6440-00-5002

Section 2 - 5

5400-00-5025 Global Parts Kit With discs, fillers, and blocking pins

Key-In-Knob Cylinders - 5400 Series

MERICAN Padlocks - see page 2 - 21

AMEROCK Same as Arrow retrofits listed below

ARROW H, L, S & W knobs and levers,

Q and M series levers

5400-xx-1099 uncombinated and use:

6-pin 140

"99" plug & shell

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

ARROW M series Tudor and Darrin

5400-xx-1006 uncombinated and use:

1590-80-2000 SD/3A tailpiece, vertical

ARROW M series Ball knobs

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, vertical 3450-80-2003 spacing washer

SD/3A

SA/3B

large diameter

plug requires

J or K series

bottom pins

"06" plug & shell

SD/3A

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

ARROW Single cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-00-2000 lost motion tailpiece 3450-80-2004 timing washer

"99" plug & shell

Product Information

large diameter

plug requires J or K series

bottom pins

Section 2 - 6

Key-In-Knob Cylinders - 5400 Series

ARROW Double cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-00-2002 long double cylinder lost motion tailpiece standard for 13/4" doors 3450-80-2004 timing washer

450-00-2001 short double cylinder lost motion

tailpiece included for 1

NOTE: File shutter tab slightly on inside cylinder housing to allow clearance for bottom peak.

/8" doors

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

CAL-ROYAL BA grade 2 knobs

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, horizontal 3450-80-2003 spacing washer

SA/3B

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

CAL-ROYAL CGN grade 1 levers and SL grade 2 levers

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

SD/3A

NOTE: Sometimes the drivehole will not accept the Peaks®tailpiece without first filing it narrower top to bottom.

Product Information

CAL-ROYAL LSD single cylinder deadlocks

LSDD double cylinder deadlocks

5400-xx-1095 uncombinated and use: Cal-Royal tailpieces

Cal-Royal tailpieces are not supplied.

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"95" plug & shell

with

small plug face

large diameter

plug requires

J or K series

bottom pins

CORBIN CK4200 grade 1 knobs, UT5200 Unit locks RUSSWIN 5400-xx-1004 uncombinated

Contact Kaba about applications prior to 1972.

Section 2 - 7

Key-In-Knob Cylinders - 5400 Series

CORBIN CL3300 grade 1 levers

USSWIN 5400-xx-1099 uncombinated and use:

"99" plug & shell

4700-80-2001 SA/3B tailpiece, vertical 3450-80-2003 spacing washer

r, the original Corbin Russwin

o tailpiece may be used.

Note: Not for use on G3 exit trim.

CORBIN CL3400, CL3600 grade 1 levers, RUSSWIN Lever trim A5, N5 for ED8000 exit devices

5400-xx-1099 uncombinated and use:

4700-80-2002 S/3C tailpiece, vertical 3450-80-2003 spacing washer

If spacer supplied by Corbin Russwin is missing, substitute Kaba 3400-00-2009 security bushing.

CORBIN CL3800 grade 2 levers RUSSWIN

5400-xx-1099 uncombinated and use:

the original Corbin Russwin tailpiece and plastic tailpiece bushing.

Corbin Russwin tailpiece and bushing not supplied.

SA/3B

S/3C

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

CORBIN CL3900 grade 2 levers RUSSWIN 5400-xx-1055 uncombinated

FALCON B Series grade 2 levers

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

SD/3A

Product Information

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Section 2 - 8

Key-In-Knob Cylinders - 5400 Series

FALCON D Series deadlocks; use Falcon tailpieces

5400-xx-1095 uncombinated and use:

Single cylinder functions:

alcon TP-10 tailpiece (A28350-000-00)

F and retainer TPR-4 (A08385-000-00)

Double cylinder functions: Falcon TP-9 tailpiece (A24350-007-00) and retainer TPR-2 (A14351-000-00)

Falcon tailpieces not supplied.

FALCON F Series levers & N Series knobs

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

"95" plug & shell

with

small plug face

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

FALCON LY grade 1 levers (same as early model imported PDQ lever)

5400-xx-1099 uncombinated and use additional Kaba parts:

4700-80-2001 SA/3B tailpiece, vertical 3450-80-2003 spacing washer two 4700-00-4007 metal washers, tailpiece

SA/3B

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Product Information

FALCON RU Series grade 1 Unit lock

5400-xx-1099 uncombinated and use Falcon parts. Install Falcon driver and tailpiece.

Most functions use Falcon no. 030730-001-30 RU 381 inside cylinder only use Falcon no. 030730-003-30 RU571 only use Falcon no. 030730-005-30

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Falcon parts are not supplied.

Section 2 - 9

Key-In-Knob Cylinders - 5400 Series

ALCON S Series grade 2 knobs, except Hana

5400-xx-1099 uncombinated and use:

4700-80-2004 FS tailpiece, horizontal

450-80-2003 spacing washer

Original Falcon tailpiece TP-2 or TP-3 with Falcon retainer TPR-1 may be used.

FALCON S Series grade 2, Hana knobs

5400-xx-1099 uncombinated and use:

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

4700-80-2006 FH tailpiece, horizontal 3450-80-2003 spacing washer

Or, use Falcon tailpiece TP-3 or TP-4 with Falcon retainer TPR-1.

FALCON T Series, grade 1 levers

5400-xx-1099 uncombinated and use:

Most functions use Falcon no. 030730-001-30 T381 inside cylinder only use Falcon no. 030730-003-30 T571 only use Falcon no. 030730-005-30

Falcon parts are not supplied.

FALCON X Series grade 1 knobs, except Hana

5400-xx-1099 uncombinated and use:

4700-80-2003 FX tailpiece, horizontal 3450-80-2003 spacing washer

Or, use Falcon tailpiece TP-1, TP-3, or TP-5 with Falcon retainer TPR-1.

Falcon parts are not supplied.

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

FALCON X Series grade 1, Hana knobs

5400-xx-1006 uncombinated* and use:

4700-80-2006 FH tailpiece, horizontal 3450-80-2003 Spacing Washer or, use Falcon TP-2, TP-4 or TP-6 with retainer TPR-1

*Note: When ordering cylinder uncombinated, FH tailpiece must be requested. Note: When replacing 7-pin Falcon cylinder, a 6-pin Falcon cylinder spacer must be used.

Falcon parts are not supplied.

"06" plug & shell

Product Information

Section 2 - 10

Key-In-Knob Cylinders - 5400 Series

FALCON Older X Series grade 1 knobs and unit locks

with one-piece (capless) knobs and knob hole bushings

5400-xx-1095 uncombinated and use:

3450-80-2003 spacing washer

use existing tailpiece from Falcon cylinder, horizontal. Note: If Falcon tailpiece needs replacement, Kaba FX tailpiece (4700-80-2003) can be used, but must be ordered separately.

KABA 1411 padlock

5400-xx-1099 uncombinated* and use:

1410-82-2000 P tailpiece horizontal 3450-80-2003 spacing washer

*Note: When ordering cylinder uncombinated, P tailpiece must be requested.

"95" plug & shell

with

small plug face

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

LSDA LH1000 grade 1 knobs

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Product Information

LSDA LX1000 grade 1 levers, L100 grade 2 levers,

600 series 'clutch' lever (1998)

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Section 2 - 11

Key-In-Knob Cylinders - 5400 Series

SDA LX1000 grade 1 levers (prior to 1994)

Field modification required.

5400-xx-1099 uncombinated and use:

3450-80-2003 spacing washer 1590-80-2000 SD/3A tailpiece, vertical, modified as shown

LSDA (LS)100B, 100P and 100T grade 2 knobs

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, horizontal 3450-80-2003 spacing washer

cut away

SD/3A

cut away

SA/3B

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

LSDA Single cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-00-2000 lost motion tailpiece 3450-80-2004 timing washer or use LSDA tailpiece and driver.

LSDA Double cylinder deadlocks

5400-xx-1099 uncombinated and use:

LSDA tailpiece assembly.

LSDA double cylinder tailpiece assembly not supplied.

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

Product Information

Section 2 - 12

Key-In-Knob Cylinders - 5400 Series

MARKS 110, 120 Series cylindrical locks

5400-xx-1099 uncombinated and use:

700-80-2001 SA/3B tailpiece, horizontal

4 3450-80-2003 spacing washer

MARKS 130 Series deadlocks

5400-xx-1099 uncombinated and use: Marks tailpieces.

13/8" to 11/2" door: Marks tailpiece 1353-L 15/8" to 17/8" door: Marks tailpiece 1354-L 2" to 21/4" door: Marks tailpiece 1355-L

Marks tailpieces are not supplied.

SA/3B

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

MARKS 170, 190, 195 Series levers, 210 Series knobs

5400-xx-1099 uncombinated and use: Marks tailpieces.

All functions except DA, DC, S: Marks tailpiece A1903-C (C9) Functions DA, DC, S: Marks tailpiece A1903S-C (SC9)

Marks tailpieces are not supplied.

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

MASTER Padlocks - see page 2 - 21

Product Information

NEW Brass padlock - See Kaba 1411 padlock page 2 - 21 STANDARD

OMNILOCK Knob, key by-pass

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Section 2 - 13

Key-In-Knob Cylinders - 5400 Series

OMNILOCK Lever, key by-pass

5400-xx-1099 uncombinated and use:

"99" plug & shell

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

PDQ SK, SP & ST levers (U.S.A.)

5400-xx-1099 uncombinated and use:

4700-80-2002 S/3C tailpiece, vertical 3450-80-2003 spacing washer

PDQ Imported SV grade 2 knobs using Ilco 7056

or Lori 1539 cylinders and 3A or SV tailpieces

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer two 4700-00-4007 metal washers, tailpiece

SD/3A

S/3C

large diameter

plug requires J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

PDQ Imported grade 1 Levers (prior to U.S.A. Spirit Levers)

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, vertical 3450-80-2003 spacing washer two 4700-00-4007 metal washers, tailpiece

SA/3B

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

Section 2 - 14

Product Information

Key-In-Knob Cylinders - 5400 Series

SARGENT 10* Line levers, 2000 exit device trim

6500* Line,6 Line grade 2 knobs, except Ball

5400-xx-1095 uncombinated and use:

4700-00-4008 neoprene washer

590-80-2000 SD/3A tailpiece, vertical

1 3450-80-2003 spacing washer *10 Line, 6500: remove Sargent nylon or plastic spindle bushing and place washer #4700-00-4008 over tailpiece before installing cylinder.

SARGENT 6 Line grade 2 Ball knobs

5400-xx-1010 uncombinated and use:

4700-80-2001 SA/3B tailpiece, vertical 3400-00-2009 spacing washer

SARGENT 5500 Line imported grade 2 knobs

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

SA/3B

"95" plug & shell

with small diameter

plug face

large diameter

plug requires

J or K series

bottom pins

"06" plug & shell

"99"plug & shell

large diameter

plug requires

J or K series

bottom pins

SARGENT 7, 8 & 9 Line grade 1 knobs

5400-xx-1008 uncombinated and use:

security bushing

3400-00-5108 adapter assembly

Product Information

3400-00-2009 security bushing

Roll pin should protrude from this side

small diameter

plug face required

SARGENT 465, 485, 486 single cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-00-2000 lost motion tailpiece 3450-80-2004 timing washer

Section 2 - 15

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

Key-In-Knob Cylinders - 5400 Series

SARGENT 464, 484 double cylinder deadlocks

5400-xx-1099 uncombinated and use:

450-00-2002 long double cylinder lost motion tailpiece standard for 1

3 3450-80-2004 timing washer

450-00-2001 short double cylinder lost motion

tailpiece included for 1

thick doors

NOTE: Slightly file shutter tab on inside cylinder h

ousing to allow clearance for bottom peak.

SARGENT 7600 Series Integralock

5400-xx-1076 uncombinated

SCHLAGE A Series, grade 2 non-Orbit knobs

5400-xx-1099 uncombinated and use:

4700-80-2001 SA/3B tailpiece, horizontal 3450-80-2003 spacing washer

thick doors

/4"

/8"

SA/3B

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

small diameter

plug face required

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

SCHLAGE A Series, grade 2 Orbit knob

3400-xx-1099 uncombinated and use:

4700-80-2002 S/3C tailpiece, horizontal 3450-80-2003 spacing washer

S/3C

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

Product Information

Section 2 - 16

Key-In-Knob Cylinders - 5400 Series

SCHLAGE AL Series grade 2 levers

5400-xx-1099 uncombinated and use:

"99" plug & shell

4700-80-2001 SA/3B tailpiece, vertical

450-80-2003 spacing washer

SA/3B

SCHLAGE B100, B400 E, EB, F160, MD single cylinder

deadlocks, S200 and H locksets

5400-xx-1099 uncombinated and use:

3450-00-2000 lost motion tailpiece 3450-80-2004 timing washer

SCHLAGE B100, B400, E, EB, Fi60 and MD double cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-80-2004 timing washer 3450-00-2002 long double cylinder lost motion tailpiece for 13/4" thick doors or 3450-00-2001 short double cylinder lost motion tailpiece for 13/8" thick doors

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

SCHLAGE B600, B700 and B800 single cylinder deadlocks

5400-xx-1099 uncombinated and use:

3450-00-2000 lost motion tailpiece 3450-80-2004 timing washer

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

SCHLAGE B600, B700 and B800 double cylinder deadlocks,

Product Information

5400-xx-1099 uncombinated and use:

3450-80-2004 timing washer 3450-00-2002 long double cylinder lost

motion tailpiece for 1

/4" thick doors or

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

3450-00-2001 short double cylinder lost

motion tailpiece for 1

/8" thick doors

SCHLAGE C & D Series grade 1 knobs

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Section 2 - 17

Key-In-Knob Cylinders - 5400 Series

SCHLAGE C & D Series, and Vandlgard grade 1 levers

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

SCHLAGE S Series grade 2 levers

5400-xx-1099 uncombinated and use:

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Schlage parts: Schlage S series driver S605-228 Schlage cylinder sleeve S605-192

Schlage parts are not supplied.

SELECT or 2000 Series deadlocks MEDECO All-N-One deadlocks

5400-xx-1099 uncombinated and use: no attachments.

These locks also accept Peaks 5800 or 5900 series small format interchangeable cores.

TRILOGY 2700, 3000 levers

5400-xx-1006 uncombinated and use:

4700-80-2005 E tailpiece, vertical 3400-00-4008 security washer, plug

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

"06" plug & shell

TRILOGY 2500 bypass, knob designs prior to 5-97

5400-xx-1099 uncombinated and use:

1590-80-2000 SD/3A tailpiece, horizontal 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

Section 2 - 18

Product Information

Key-In-Knob Cylinders - 5400 Series

TRILOGY 2500 bypass, lever designs prior to 5-97

5400-xx-1099 uncombinated and use:

590-80-2000 SD/3A tailpiece, vertical

1 3450-80-2003 spacing washer

ULTRA 7000 Ball knob

5400-xx-1099 uncombinated and use:

D/3A

"99" plug & shell

large diameter

plug requires

J or K series

bottom pins

1590-80-2000 SD/3A tailpiece, vertical 3450-80-2003 spacing washer

SD/3A

"99" plug & shell

large diameter

plug requires J or K series

bottom pins

WEISER D 9370 and 9470 series deadlocks; use Weiser tailpieces

5400-xx-1095 uncombinated and use:

"95" plug & shell

Weiser tailpiece and retainer.

Weiser parts are not supplied.

Product Information

VON DUPRIN 22 Series exit device knob trim

with

small plug face

large diameter

plug requires

J or K series

bottom pins

5400-xx-1099 uncombinated and use:

4700-80-2002 S/3C tailpiece, horizontal 3450-80-2003 spacing washer over tailpiece

Section 2 - 19

S/3C

"99"plug & shell

large diameter

plug requires

J or K series

bottom pins

Key-In-Knob Cylinders - 5400 Series

YALE 6100 and 6200 series Monolocks

Retrofit for Yale No. 1801 cylinder

5400-xx-1055-(Yale monolock) uncombinated

ame as 5400-xx-1054-54 cylinder below,

S but without rollpin and spacer.

YALE 5400 grade 1 knobs and 5300 grade 2 knobs

Retrofit for Yale No. 1801 cylinder

5400-xx-1054 uncombinated

Same as 5400-xx-1055-55 cylinder below, but without tailpiece.

YALE 5400LN grade 1 levers

5400-xx-1055 uncombinated 3425-82-3012 tailpiece 3425-00-4012 retainer pin (1/16" roll pin)

Same as 5400-xx-1054 cylinder above but with tailpiece.

YALE 5300L grade 2 levers

Field modification required.

5400-xx-1095 uncombinated then modify

4700-80-2001 SA/3B tailpiece, vertical 3450-80-2003 spacing washer

Modify tailpiece using Yale tailpiece as a template.

YALE 5300LN grade 2 levers

5400-xx-1095 uncombinated

3450-80-2003 spacing washer 3450-00-2000 lost motion tailpiece, vertical

SA/3B

cut line

"95" plug & shell

with

small plug face

large diameter

plug requires

J or K series

bottom pins

"95" plug & shell

with

small plug face

large diameter

plug requires

J or K series

bottom pins

Product Information

Section 2 - 20

Padlocks – Key-In-Knob Cylinders

ote: The Peaks Global system is designed to provide dealers an exclusive keyway for conventional cylinders.

N The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

6-pin 140

Kaba 1411 or New Standard 5400-xx-1099 cylinder with Kaba P tailpiece

The following can be made from 5400-xx-1099 cylinder kit using OEM drivers:

Master ProSeries Use adapter #0298-0628 from Master. Schlage PL series Use padlock driver from Schlage. Schlage old style 45-101 Use padlock driver from Schlage.

The following can be made from 5400-xx-1006 cylinder kit using OEM adapters:

Master System 29 Use with adapter from Master Master Pro Series Use adapter #0298-0626 from Master. American 3600 & 3700 Use with modified adapter. See below.

Lori adapter may also be modified.

American padlocks

Use 5400-xx-1006 cylinder.

Shorten Medeco adapter .050"

1. "L" adapter 2. shorten adapter* 3. notch for key tip

*Dealers have reported that shortening isn't always necessary.

Made with the "99"

Made with the "06"

and retainer ring

Product Information

Section 2 - 21

Padlocks – Interchangeable Cores

ote: The Peaks Global system is designed to provide dealers an exclusive keyway for conventional cylinders.

N The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

padlocks with small format 6-pin 140 interchangeable core

5800 or 5900 series cores fit any padlock prepared for 6-pin ICore, including:

Abus 381C/45 Best (Except .150" Spacing) Wilson Bohannon American 3200 & 3500 series Falcon Arrow Master Proseries 6400 & 6500

For 6-pin core in 7-pin housing, use spacer 3800-00-3007

padlocks with large format 6-pin 140 interchangeable cores

Corbin Russwin PL5070 padlocks: use 5140

Yale 424 and 434 padlocks: use 5240

Medeco 50 series brass padlocks: use 5340

Schlage PL4XXX series padlocks: use 5440

Sargent 758 Padlocks use 5540

Cabinet Locks and Specialty Applications

5800 and 5900 small format interchangeable cores can be installed in most cabinet locks, mailbox locks and switch locks prepped for small format interchangeable core.

Olympus cabinet lock with Corbin Russwin large format interchangeable cores prep: use 6140 series large format interchangeable cores

Olympus 720, 721, 722 & 728 series: use 5800 or 5900 series small format interchangeable cores

Olympus 700 & 800 series cabinet locks: use 5400-xx-1099 with Olympus 78-Kaba-Conv Kit

Product Information

Schlage CL1000 and CL2000 series: use 5400-xx-1099 with Schlage tailpiece and driver

Section 2 - 22

Small Format Interchangeable Cores (Capped) - 5800 Series

ote: The Peaks Global system is designed to provide dealers an exclusive keyway

N for conventional cylinders. The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

brass plug

- brass shell and control sleeve

- capped pin chambers

- individual chambers may be emptied with ejector tool

- 140 capping block / press required

- face of plug is key stop for longer core life

- retrofits Arrow, Best, Falcon, KSP, or Lockwood small format interchangeable cores prep

uncombinated: 5840-xx-1006 140, 6-pin

Uses: 3800-00-4221 individual caps 3425-00-4002 C-ring plug retainer For 6-pin core in 7-pin housing, use spacer 3800-00-3007

Small Format Interchangeable Cores (Spring Loaded) - 5900 Series

Note: The Peaks Global system is designed to provide dealers an exclusive keyway for conventional cylinders. The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

6-pin 140

- brass plug

- alloy shell and control sleeve with patented plating and coating

- spring cover retains pins and springs

- 6840-00-3540 staking fixture and 6440-00-4001 staking tool required

- face of plug is key stop for longer core life

- retrofits Arrow, Best, Falcon, KSP or Lockwood small format interchangeable cores prep

Uses:

uncombinated: 5940-xx-1006 140, 6-pin

6800-00-2006 6-pin, or 6800-00-2007 7-pin spring covers 3425-00-4002 C-ring plug retainer For 6-pin core in 7-pin housing, use spacer 3800-00-3007

Large Format Interchangeable Cores for Corbin Russwin - 5140 Series

Note: The Peaks Global system is designed to provide dealers an exclusive keyway for

Product Information

conventional cylinders. The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

- brass plug

- alloy shell and control sleeve with patented plating and coating

- spring cover retains pins and springs

- 6840-00-3540 staking fixture and 6440-00-4001 staking tool required

- face of plug is key stop for longer core life

- no restricted control combinations

6-pin 140

- This product uses a large diameter plug. J series bottom pins required for A2 system pinning. K series bottom pins required for A4 system pinning.

uncombinated: 5140-xx-1006 140, 6-pin

Section 2 - 23

Uses: 3425-00-2006 mortise/rim spring cover 6140-00-4002 C-ring plug retainer

Large Format Interchangeable Cores for Yale - 5240 Series

ote: The Peaks Global system is designed to provide dealers an exclusive keyway for

N conventional cylinders. The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

- brass plug

- alloy shell and control sleeve with patented plating and coating spring cover retains pins and springs

- 6840-00-3540 staking fixture and 6440-00-4001 staking tool required

- does not

- face of plug is key stop for longer core life

- retrofits Medeco 31

require a special extended tip control blank

6-pin 140

uncombinated: 5240-xx-1006 for Yale 1210 140, 6-pin 5240-xx-1007 for Yale 1220 140, 6-pin

NOTE: Yale cores are not interchangeable across Yale's product line. It must be determined if you are replacing a Yale 1210, 6-pin core, or a Yale 1220, 7-pin core.

5240-xx-1006 retrofits Yale 1210 in 6-pin housings ONLY

1 5/16"

Use: 3425-00-2006 mortise/rim spring cover 6240-00-4002 C-ring plug retainer

5240-xx-1007 retrofits Yale 1220 in 7-pin housings ONLY

1 1/2"

Large Format Interchangeable Cores for Medeco 32 - 5340 Series

6-pin 140

uncombinated: 5340-xx-1006 140, 6-pin

- brass plug

- alloy shell and control sleeve with patented plating and coating

- spring cover retains pins and springs

- 6840-00-3540 staking fixture and 6440-00-4001 staking tool required

- no forbidden or mandatory control combinations

- face of plug is key stop for longer core life

Uses: 6340-00-4012 timing pin 6340-00-4002 C-ring plug retainer 6800-00-2007 7-pin ICore spring cover

Section 2 - 24

Product Information

Removable Cores for Schlage - 5440 Series

ote: The Peaks Global system is designed to provide dealers an exclusive keyway

N for conventional cylinders. The Peaks Global key also works in conjunction with Kaba’s Peaks Classic Interchangeable & Removable Cores for installations requiring a mix of cylinder formats.

brass plug

- alloy shell and control sleeve with patented plating and coating

- spring cover retains pins and springs

- 6440-00-3540 staking fixture and 6440-00-4001 staking tool required

- pins like original small format interchangeable cores; A2 system stacks to 26

- face of plug is key stop for longer core life

- 6440-00-2000 spring cover (same as mortise/rim)

- 6140-00-4002 C-ring plug retainer

5440-xx-1006: uncombinated

Note: Dedicated pin kit #6440-00-5002 required: Available for A2 system pinning only.

Use: 6440-00-2000 spring cover 6140-00-4002 C-ring plug retainer

6-pin 140

Removable Cores for Sargent - 5540 Series

- brass plug

- alloy shell and control sleeve with patented plating and coating

- spring cover retains pins and springs

- 6840-00-3540 staking fixture and 3400-00-4001 staking tool required

- pins like original small format interchangeable cores; A2 system stacks to 26

- no forbidden or mandatory control combinations

- face of plug is key stop for longer core life

5540-XX-1006: uncombinated

Product Information

top view of core

Install timing pin here.

Use: 6340-00-4012 timing pin 6800-00-2007 7-pin small format interchangeable cores spring cover 6140-00-4002 C-ring plug retainer

Timing pin engages slot in sleeve to create positive key pull stop for control key.

6-pin 140

Section 2 - 25

Product Specifications and Testing Data

For specification purposes, 6-pin Peaks Global products have seven active pin stacks. Texts of product specifications are available upon request.

echanical Testing

Testing of 5900 series cores has proven them to be superior to the 5800 series cores. The modern alloys used in the shells and sleeves of the 5900 series have remarkable bearing properties. In addition, Kaba employs a patented two step process of plating and cladding on all 5900 and 5800 sleeves and shells that makes the surfaces of these components harder than conventional brass surfaces. Plugs for both 5900 and 5800 series are made of brass because of its machinability.

Peaks cores and cylinders exceed 500,000 cycles with no measurable wear on shells and sleeves. Keys, keyways and bottom pins show normal wear. When 5900 series cores are cut open, tool marks remain visible in the pin chambers.

Pull tests have been successfully completed on Peaks cores in Arrow, Best, KSP, Corbin Russwin, Medeco and Yale housings. The 5900 cores actually require more force than 5800 series cores. This is due to the behavioral characteristics of the metals. All brass tends to shear, while the alloys employed in the 5900 tend to distend but hold.

Environmental testing

The standard ASTM B117 salt spray (corrosion) test for trim is 200 hours. After over 300 hours, both control and operating keys work in Peaks cores, even before lubrication. After lubrication, the cores feel like new. Chrome finish cores do not discolor. Brass finish cores turn dark with exposure to the elements.

Product in development, warranty and updates

The catalog indicates current product availability. Product is always under development. Contact Kaba Access Control about retrofits not currently shown. The last page of the catalog is a one page summary of pinning components. Warranty and return policies are in the catalog.

Product Information

Section 2 - 26

Peaks®Global

Notes

Product Information

Section 2 - 27

Technical Manual Section 3: Key Cutting and Pinning

Lubricating the Plug

pply a small amount of Superlube™ (5400-00-4202) to fingertip and lightly grease Global Plug.

A The lubricant acts as a fixative to hold the parts in place during assembly. Only apply lubricant to the following areas:

a. the filler holes b. disc slots along the sides of the plug c. blocking pin area at the rear of the plug

Note: Do NOT

apply any lubricant to the top pin-hole area of the plug.

Filler holes

Bottom pin

Disc slot

Top pin hole – Do NOT apply lubricant to the top pin-hole area of the plug

Determining Node and Disc Positions

Use the ".140 spacing" end of the Peaks Multi-Key gauge (part number 3800-00-4050) to determine node locations on your Peaks Global key blank. The node pattern for Peaks Global keys is numbered bow to tip. All other Peaks Global references including key bitting numbers are always read as tip to bow. Record the node pattern for both sides of the key as shown in the illustration.

Key Cutting & Pinning

Key shown has nodes in 1, 4 and 5 positions

Key shown has node in 2 position

Section 3 - 1

Installing Blocking Pins, Discs and Fillers – Conventional Cylinders

Inserting Blocking Pins

Insert two blocking pins (part number 5800-00-4010) into the blocking pin holes at the rear of the plug on both sides.

Blocking pin

Inserting Discs and Fillers

Insert discs (part number 5400-00-4002) into the Global plug disc slots that correspond with each node position on both sides of the key. Orient discs with tabs toward the bottom of the plug. Place appropriate filler plates in the filler holes where no discs are positioned. (Note that the filler plates are concave.)

Fillers

Discs

Global Assembly

Insert the plug into the housing or cylinder for final assembly.

Key Cutting & Pinning

Section 3 - 2

Installing Blocking Pins, Discs and Fillers – Interchangeable Cores

Inserting Blocking Pins

Insert blocking pins in the blocking pin holes on each side closest to the front of the plug that will not interfere with the node pattern on your Peaks Global key. These blocking pins prevent unauthorized keys with an improper node pattern from being fully inserted into the cylinder.

Blocking pin

Inserting Discs and Fillers

Cores for small and large format interchangeable cylinders only have disc slots in the first position of the plug on both sides which is due to the internal geometry of these cores. These plugs will always have a disc present in either or both of these first slots. Insert one or two discs (part number 5800-00-4001 for small format plugs or 5400-00-4002 for large format plugs) into the first disc slots as needed to correspond to nodes on the side of the key. Place #1 filler plates in the filler holes where no discs are positioned.

Filler

Disc

Key Cutting & Pinning

SERVICE NOTE: REFRAIN FROM USING ANY MASTER PINS LESS THAN 0.038 IN NODE LOCATIONS. NO #2 MASTER PINS.

Section 3 - 3

Inserting Peaks Patented Bottom Pins in Small Format Interchangeable Cores

Inserting Peaks Patented Bottom Pin

Insert key into plug. Insert patent bottom pin into plug as shown. Lay assembly aside carefully to ensure pin remains in plug.

Patent Bottom Pin

Key Cutting & Pinning

Section 3 - 4

Inserting Peaks Patented Bottom Pins in Small Format Interchangeable Cores

Inserting Peaks Pins

Place the Plug Follower (part number 3400-00-4003) into core (as shown). Position the slot at end of Plug Follower to align with Peaks Pin hole. Insert spring into pin hole.

Top Pin (Positioned bevel toward spring)

Spring

Peaks Pin Hole

Plug Follower with spring resting in slot.

Position top pin into plug follower slot. With pin depressed into pin hole, slide follower half way through plug.

Key Cutting & Pinning

Section 3 - 5

Inserting Peaks Patented Bottom Pins in Small Format Interchangeable Cores

Orient Key and plug assembly as shown with patented bottom pin facing upward. Orient the cylinder assembly as shown with Kaba logo facing down.

Slide key and plug assembly into cylinder assembly – pushing Plug Follower out the back of casing.

Note: Use core to hold cylinder assembly components (cylinder and change key barrel) in place while

inserting key and plug assembly.

Secure plug in cylinder assembly with E-ring as shown. Tab in center of ring should be positioned to fit notch in base of keyway. Push ring securely into place.

E-ring

Key Cutting & Pinning

Section 3 - 6

Cylinder Stamping, Marking, Lubrication & Tailpiece Installation

Stamping and Marking

Kaba Access Control recommends marking cylinders with an indelible marker. If stamping or engraving of cast cylinders is unavoidable the stamped or engraved area must be coated with a clear acrylic enamel (Krylon, fingernail polish, etc.). Application by brush is preferable, but spray is acceptable as long as care is taken to reduce overspray. Key-in-knob cylinders should never be stamped. Cores should be stamped on the top half of the shell. Mortise and rim cylinders should be stamped on the back of the shell.

Stamp here

Rim cylinder

Stamp here

Mortise cylinder

Do not stamp

anywhere

Key-in-Knob

cylinder

Stamp here

Interchangeable Core

Lubrication

Kaba recommends the use of Superlube™ for all Peaks Global cylinders. It should only be applied sparingly to the slots and indentions where discs and fillers are to be inserted.

Tailpiece Installation

Tailpiece inserted correctly, allowing

tip of key full insertion.

Correct Incorrect

Key Cutting & Pinning

When inserting tailpiece horizontally it can be flipped either way for proper operation.

Section 3 - 7

Tailpiece inserted

upside down,

preventing full key

insertion.

Key Bitting Specifications

Stops

Peaks Global keys have two stops, a bow stop and a tip stop. The bow stop gauges keys in all current prod-

cts. The tip stop gauges only in non-domed face small format interchangeable cores made prior to March,

1996. Either stop may be used when code cutting depending on the machine employed.

Most Peaks key sections are paracentric and not designed to be clipped on a key bitting punch. Paracentric keyways are preferred for their enhanced pick resistance. They also produce many more keyway variations than flat bladed keys.

Factory bittings are tip to bow

Factory bitting lists are written tip to bow. When using card-type key machines such as the Ilco Universal II or HPC 1200 CM, it is suggested that keys be cut bow to tip to lessen the effects of the backlash of the rackand-pinion mechanism. Care must be taken in reversing bittings written as tip to bow.

Tolerances and milling cutters

Peaks tolerances are tighter than most other brands. Both depth and spacing must be held within +/- 0.002" for proper operation. Key machines must be kept in precise adjustment. The required cutter angle is 90 degrees for proper key insertion. A cut root flat of .046" is required. The 90MC or equivalent cutter is recommended.

Position next to the Peak

In the position next to the Peak, cuts deeper than a #6 in the A2 system or a #3 in the A4 system require the use of an asymmetrical cutter, such as the #1011.

The 90MC cutter can not be used as it removes the upper Peak when making these deep cuts next to the Peak.

7 8 9

MACS

140 A2 MACS is 8. 140 A4 MACS is 4.

Depth and spacing data

Depths .140 Spacing

A2 A4 from tip from bow 0 .318" .318" 1 .136" 1.030" 1 .305" .297" 2 .276" .890" 2 .293" .276" 3 .416" .750" 3 .280" .255" 4 .556" .610" 4 .268" .234" 5 .696" .470" 5 .255" .213" 6 .836" .330" 6 .243" 7 .230" 8 .218" 9 .205"

Key Cutting & Pinning

Section 3 - 8

Cutting Keys by Code

Peaks tolerances are tighter than most other brands. Both depth and spacing must be held within +/-

.002" for proper key operation. Key machines should be periodically gauged to maintain tolerances.

Framon #2

Contact Framon at 517-354-5623 regarding a Peaks tip stop. Use the bitting specifications in this manual.

Framon KX-1

The KX-1 cuts 140 - 6 pin keys

Framon FRA-2001

This machine is computer operated and a Peaks vise jaw is required.

HPC Codemax

The following are the correct DSD numbers for Peaks.

140, 6-pin A2 DSD608, A jaw/red tip stop A4 DSD612, A jaw/red tip stop

Codemax cuts all keys bow to tip. Peaks systems are written tip to bow. Reverse the bittings on factory lists.

HPC/LaGard 1200CM

HPC manufactures the following A2 system card for Peaks:

140, 6-pin: HPC card number CPKS1 red tip stop, standard A jaw

The modified B vise jaw required to cut Peaks keys on the 1200CM is available from Kaba.

Spacing on HPC cards is bow to tip. When using a factory bitting list, reverse the bittings. In December 1996, HPC began to provide a calibration kit for the 1200, part no. CMB-CK. A spacing calibration key is available from Kaba to check the accuracy of the space adjustment. Because of rack-and-pinion backlash, better keys may be produced by reversing the bittings and cutting bow to tip.

ITL9000

Machines purchased after September 1992 already have Peaks data installed and the key rest milled to accommodate the bottom peak.

Key Cutting & Pinning

ILCO Universal II

Use 0.140" spacing disc. The 0.0125" depth disc is used for A2 system. The 0.021" depth disc is used for A4 system. Use tip stop on the 27B key rest. For 6-pin keys, chamfer the corner of the key rest for bottom peak clearance.

Duplication

Automatic duplicating machines like the ILCO #017 currently require field modification of the vise jaw for the bottom peak. As of August 1992, Rytan machines are manufactured with a divot in the jaw.

Section 3 - 9

Components for Pinning

Peaks products may be pinned to the A2 or A4 system. The patent pin stack is built into the face of all small format interchangeable cores. In large format interchangeable cores and conventional cylinders, the patent

ins are installed when combinating. Certain products have a large diameter plug and require longer bottom

p pins. All products use the same top pins.

Patent pins

3425-00-3002 7B patent top pin for conventionals

3800-00-3004 patent bottom pin for all products except those with large diameter plugs

3800-00-3005 patent top pin all cores

6140-00-3004 patent bottom pin for the Universal 5400-xx-1099, the 5400-xx-1095 key-In-knob and 5140 Corbin Russwin large format interchangeable core

Spring

3800-00-4010 stainless steel

for all Peaks products

Tumbler pins

Peaks pins are crowned for smooth operation and long cylinder life. Bottom pins are nickel silver. Spool pins are used to increase pick and impression resistance. Bottom pins are .003" shorter than aftermarket replacement pins. Non-original pins will not work properly in Kaba products and their use voids product warranty.

A2 system: Use A series bottom pins for everything except the 5400-xx-1095 key-in-knob, the Universal 5400-xx-1099 key-in-knob cylinder and the 5140 Corbin Russwin large format interchangeable core with large diameter plugs. J series bottom pins are required for products with large diameter plugs. Use B series master/top pins for all products.

0A 1A 2A 3A 4A 5A 6A 7AS 8AS 9AS

J series bottom pins are for the large diameter plugs only. 0J thru 4JS are the same as 5A thru 9AS, respectively.

0J 1J 2JS 3JS 4JS 5J 6J 7J 8J 9J

A4 system: Use E series bottom pins for everything except the 5400-xx-1095 key-in-knob, the Universal 5400-xx-1099 key-in-knob cylinder and the 5140 Corbin Russwin large format interchangeable core with large diameter plugs. K series bottom pins are required for products with large diameter plugs. Use F series master/top pins for all products.

K series bottom pins are for the large diameter plug only. 1K and 2K are the same as 4ES and 5ES, respectively.

1KS 2KS 3K 4K 5K

0E 1E 2E 3E 4ES 5ES

Spring covers

Spring covers are curved. Install them by flattening with the 3400-00-4001 staking tool.

3425-00-2000 key-in-knob

3425-00-2006 mortise, rim, Corbin Russwin and Yale large format interchangeable cores

6800-00-2006 6-pin 5900 small format interchangeable cores

6800-00-2007 7-pin 6800 small format interchangeable cores, 5340 Medeco large format interchangeable cores

Universal pin kits

Peaks universal pin kits (3400-00-5012 for A2 and 3400-00-5004 for A4) contain all of the components required to pin any uncombinated cylinder or core, including the 6340-00-4012 timing pin for the 5340 large format interchangeable core for Medeco.

Key Cutting & Pinning

Section 3 - 10

Pin Lengths and Stack Heights

Pin series and uniform stack heights for A2 and A4 systems

product

system

A2 system stack total 26 26 31 23 26 26 top pins B series B series B series B series B series B series bottom pins A series J series A series A series J series A series

A4 system stack total 15 15 18 14 15 15 top pins F series F series F series F series F series F series bottom pins E series K series E series E series K series E series

5400 key-in-knob 5400-xx-1099 5401/5402 5800 5140 Corbin 5240 Yale

xcept

e 5400-xx-1099 with large mortise 5900 with large 5340 Medeco 5400-xx-1095 diameter plug and rim I/C diameter plug R/C

400-xx-1095 conventional and Russwin R/C and

Pin lengths and material

Kaba bottom pins are .003" shorter than aftermarket replacement pins. Non-original pins will not work properly and void the product warranty.

"S" indicates spool type pins. Bottom pins are nickel silver. Top pins are brass.

3800-00-4202 .025 2B

bottom pin

part number length A2 A2 A4 A4

3800-00-3200 .107 0A 0E

-3201 .1195 1A

-3202 .132 2A

-3203 .1445 3A

-3204 .157 4A

-3205 .1695 5A 0J 3E 0K

-3206 .182 6A 1J

-3207 .1945 7AS 2JS

Key Cutting & Pinning

3800-00-3401 .128 1E

6140-00-3205 .2325 5J 3K

6140-00-3404 .254 4K

-3208 .207 8AS 3JS

-3209 .2195 9AS 4JS

-3402 .149 2E

-3404 .191 4ES 1KS

-3405 .212 5ES 2KS

-3206 .2445 6J 3207 .257 7J

-3208 .2695 8J

-3209 .282 9J

-3405 .275 5K

3800-00-4401 .021 1F

top pin

part number length A2 A4

-4203 .0375 3B

-4204 .050 4B

-4205 .0625 5B

-4206 .075 6BS

-4207 .0875 7B

-4208 .100 8BS

-4209 .1125 9B

-4210 .125 10BS 6FS

-4211 .1375 11B

-4212 .150 12B

-4213 .1625 13B

-4214 .175 14B

-4215 .1875 15B

-4216 .200 16B

-4217 .2125 17B

-4218 .225 18B

-4219 .2375 19B

-4402 .042 2F

-4403 .063 3F

-4404 .084 4FS

-4405 .105 5FS

-4407 .147 7F

-4408 .168 8F

-4409 .189 9F

-4410 .210 10F

-4411 .231 11F

Section 3 - 11

Pinning Conventional Cylinders

Peaks conventional cylinders are designed to be top loaded. Install a patent bottom pin, small end down, and patent top pin, turned end down, in the patent chamber immediately next to the plug face. In the A2 system a

umber 7 top pin should be seated above the patent top pin. In A4 use a number 4 top pin above the patent

n top pin.

Pin stacks

onsult the charts on pages 3-18 and 3-21 for the correct pins. The

C Universal 5400-xx-1099 and the 5400-xx-1095 key-in-knob cylinder have large diameter plugs and require longer bottom pins and the 6140-00-3004 patent bottom pin. All conventional cylinders use the

o not strike

same top pins. Observe the specified pin stack heights. After loading the pins install a 3800-00-4010 stainless steel tumbler spring in each chamber.

Staking

Place the cylinder in the correct cavity of the 3400-00-4000 staking fixture. Set the correct curved spring cover in place over the springs and hold it down with the staking tool.

Using a plastic or rawhide mallet, flatten the spring cover between the flanges. Do not strike the bible flanges on key-in-knob cylinders. Bending or breaking the flanges breaks the patented hard coat on the shells and can lead to corrosion.

D bible flanges

Flatten the spring cover between them.

The chrome key-in-knob cylinder shell requires a staking tool and new curved spring cover, 3425-00-2000. Older staking tools had a thick blade. The blade must be narrowed to 0.125" to fit between the bible flanges.

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use excessive force.

These are the tools required for conventional cylinders:

The 3400-00-4002 key-in-knob

3400-00-4000 staking fixture for conventionals

.125"

3400-00-4001 staking tool

staking tool and flat spring covers are discontinued. Do not use this or similar tools on chrome key-inknob cylinders.

Key Cutting & Pinning

Section 3 - 12

Pinning Conventional Cylinders

Rekeying Conventional Cylinders

ry off and discard the spring cover. Rekey and apply a new spring cover. Since all Peaks products are

P designed to be top loaded, use of a follower for rekeying is optional.

Mortise / rim cylinder screws have a Loctite

coating. If cams or plug retainers are removed, use new

screws and tighten them firmly.

Pinning Interchangeable Cores

Pin to uniform pin stack height

Insert a key into the core and turn the plug 90 degrees. Extend the control lug into the locked position. Top load the core. Let the bottom pins stop against the plug as shown in figure 1.

All the stacks should have a uniform height. Dump any incorrect chamber and repin it. When the pin stack heights are uniform, turn the plug and let the pins drop into the plug.

1. Load pins with plug turned.

Correct

2. Uniform pin stack heights

3. Errors in 4th and 5th chambers

Incorrect

5800 series capped small format interchangeable cores

Global cores come in .140" spacing only. Place the core loaded with pins only, into the capping block. Insert a tumbler spring, 3800-00-4010, into each chamber by dropping them into the holes in the block.

One chamber at a time, place a cap on top of each spring and tap it in place with the capping tool and a plastic or rawhide mallet until the capping tool is flush against the block. Do not use excessive force. Lubricate discs with Superlube™ synthetic grease.

For 140 cores, a capping press in .140" spacing is available from Kaba.

Rekeying

Key Cutting & Pinning

Place the ejector tool into the hole under the chamber(s) and drive out the pins, spring, and cap with a light tap.

Discard the elements and repin. Always use new springs and caps.

3800-00-3548 ejector tool

3800-00-3547 capping tool is used with both blocks

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use a metal hammer.

Section 3 - 13

3840-00-3540 140 capping block (6 holes)

Pinning Interchangeable Cores

5900 series spring cover small format interchangeable

cores

Place core loaded with pins and springs into the correct cavity of the 5940-00-3540 staking fixture.

40 0 -0 0 -4 0 01

3 staking tool for use with all spring covers

Place the correct spring cover (6-pin length) over the springs.

Set the staking tool on the cover. Gently tap the cover flat with a plastic or rawhide mallet. Do not use excessive force. Superlube™ synthetic grease.

Rekeying spring cover cores: Pry up and discard the spring cover. Dump the old pins and springs. Repin and stake on a new spring cover.

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use excessive force.

6840-00-3540

staking fixture for

all 5900, 5100 and

5200 series cores

Staking technique

Capping blocks and fixtures are designed to support cores at their waist to prevent sleeves and shells from becoming out-of-round. Working without proper equipment and technique can cause deformation resulting in poor operation, and can void product warranty

• Use original pins and Kaba equipment.

• Do not use excessive force.

• Do not deform or score the shells.

5140 large format interchangeable cores for Corbin Russwin

The 5140 large format interchangeable cores for Corbin Russwin have an A2 system pin stack total of 26.

5140 cores use the large diameter plug and require the following components:

A2 system: J series bottom pins and B series top pins A4 system: K series bottom pins and F series top pins 6140-00-3004 patent bottom pin 3800-00-3005 patent top pin 3800-00-4010 stainless steel tumbler springs 3425-00-2006 mortise / rim / large format interchangeable core spring covers 5400-00-5025 for this kit which would include the following parts (qty's of each

to be determined):

5400-00-4002, lg. active disks (universal key-in-knob and lg. plug large format

interchangeable core's) 5800-00-4010, blocking pins 5400-00-4011, #1 filler 5400-00-4012, #2 filler 5400-00-4013, #3 filler

5400-00-4015, #5 filler

Top load the core in the usual manner. Stake in 6840-00-3540 staking fixture.

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use excessive force.

Key Cutting & Pinning

Section 3 - 14

Pinning Interchangeable Cores

5240 large format interchangeable core for Yale

The 5240 large format interchangeable core have an A2 system pin stack total of 26. Use 5240-xx-1006 to retrofit Yale 1210 and 5240-xx-1007 for Yale 1220.

5240 cores use the following components:

2 system: A series bottom pins and B series top pins

A A4 system: E series bottom pins and F series top pins 3800-00-3004 patent bottom pin 3800-00-3005 patent top pin 3800-00-4010 stainless steel tumbler springs 3425-00-2006 mortise / rim spring covers 5400-00-5025 for this kit which would include the following parts (qty's of each to be determined): 5800-00-4001, lg. active disks (M,R, small plug small format interchangeable core) 5800-00-4010, blocking pins 5400-00-4011, #1 filler 5400-00-4012, #2 filler 5400-00-4013, #3 filler 5400-00-4015, #5 filler

Top load the core in the usual manner. Stake in 6840-00-3540 staking fixture.

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use excessive force.

5340 large format interchangeable core for Medeco 32 Series

The 5340 large format interchangeable core have an A2 system pin stack total of 26. The 5340 series requires a timing pin, number 5340-00-4012, which must be installed during pinning. Uncombinated cores do not contain the timing pin. They can be found in the Peaks universal pin kits. Do not omit the timing pin. Omitting the timing pin will make it difficult to install the core.

5340 cores use the following components: A2 system: A series bottom pins and B series top pins A4 system: E series bottom pins and F series top pins 6340-00-4012 timing pin 3800-00-3004 patent bottom pin 3800-00-3005 patent top pin 3800-00-4010 stainless steel tumbler springs 6800-00-2007 spring cover, 7-pin 5400-00-5025 for this kit which would include the following parts (qty's of each to be determined): 5800-00-4001, lg. active disks (M,R, small plug small format interchangeable core) 5800-00-4010, blocking pins

Key Cutting & Pinning

5400-00-4011, #1 filler 5400-00-4012, #2 filler 5400-00-4013, #3 filler 5400-00-4015, #5 filler

Top load core in the usual manner. Install 3800-00-3004 patent bottom pin and 3800-00-3005 patent top pin in the patent chamber. Use 3800-00-4010 stainless steel tumbler springs in all chambers.

The 6800-00-2007 7-pin small format interchangeable core spring cover is required to contain all the components. Apply spring cover using Peaks core staking fixture and staking tool.

• Work on a firm bench surface.

• Strike tools gently with a plastic or rawhide mallet.

• Do not use excessive force.

top view of core

Install timing pin here.

Section 3 - 15

Pinning Interchangeable Cores

5440 Schlage Removable Core

The 5440 large format removable core has an A2 system pin stack total of 26.

5440 cores use the large diameter plug and require the following components:

2 system: X series bottom pins and W series top pins

A A4 system: A4 pinning not available 6140-00-3004 patent bottom pin 3800-00-3005 patent top pin 6440-00-2000 spring cover 6440-00-4010 stainless steel springs

5540 Sargent Removable Core

The 5540 large format removable core has an A2 system pin stack total of 26. The 5540 has an A4 system pin stack total of 15. The 5540 series requires a timing pin, number 6340-00-4012. Do not omit the timing pin. Omitting the timing pin will make it difficult to install the core.

5540 cores use the following components: A2 system: J series bottom pins and B series top pins A4 system: K series bottom pins and F series top pins 6340-00-4012 timing pin 3800-00-3005 patent bottom pin 6140-00-3004 patent top pin 3800-00-4010 stainless steel springs 6800-00-2007 spring cover

Timing pin engages slot

top view of core

in sleeve to create positive key pull stop

Install timing pin here.

for control key.

Key Cutting & Pinning

Section 3 - 16

Calculating Small Format Interchangeable Core – A2 System Pin Stacks

A2 system has ten depths numbered 0 to 9, shallow to deep, respectively. Two step progression must be used to prevent key interchange. In A2 system, parity must be maintained in each position, i.e., only the odd or even cuts may be used in a given pin chamber.

When a key system is written, the choice of a TMK automatically determines the parity pattern. Section 4 of this Manual has forms with all sixty-four parity patterns to use in maintaining a TMK register. This can also be done with a computer and data base program.

The operating and control shear lines are distinct in all positions. All the operating keys work at the plug (operating) shear line. Only the control key works at the control shear line.

Pin to the operating keys first. The shallow cut determines the bottom pin. A master pin makes up the difference between shallow and deep operating cuts. The numerical value of the bottom pin and master pin together is called the "plug total." For example, a #3 bottom pin plus a #4 master pin results in a plug total of 7.

Buildup pins are added to the plug total to make the control key operate at the control shear line. Top pins are added to achieve a uniform pin stack height of 23 in all chambers.

add top pin to

Calculating the pin stack

make stack total 23

3. Add a top pin to bring the total pin stack to 23.

buildup pin equals control cut + 10 minus plug total

2. Add 10 to control bitting. Subtract plug total. The remainder is the buildup pin.

1. Pin operating keys to the plug shear line. The plug total equals the deep operating bitting.

master pin equals the larger of the master key or operating key cut minus the bottom pin

bottom pin equals the smaller of the master key or operating key cuts

plug total

Key Cutting & Pinning

Section 3 - 17

Calculating Other A2 Pinning Stacks

Comparing A2 Pin Stacks

The examples on this page show pinning for key symbol 1AA.

hen pinning conventional cylinders, ignore

W the control bitting. If a top pin of 20 or greater is needed, use two pins of equal length to bring the pin stack to the required height. When an odd numbered top pin is required, such as 21, use two pins that are close in size – 11 and 10 instead of 13 and 8.

For the patent pin chamber in all conventional cylinders, insert the proper bottom and top patent pins, then insert a number 7B top pin.

Pinning for all Peaks products can now be accomplished with only one spring. That stainless steel spring is number 3800-00-4010

control CTR 779631 master AA 951473 change 1AA 593875

Stack height 31

Stack height 26

5400-XX-1206

Key in Knob

top 17 17 12 18 19 11

buildup 11 10

master 4424 - 2 bottom 551473

5400-XX-1299

"99" and "95" Key-in-Knob

top 17 17 12 18 19 11

buildup --11 --10

master 4424 - 2 bottom 551473

5401-XX-1210 Rim / Mortise

top 11 11 14 12 12 13

buildup 11 11 14 11 12 13

master 4424 - 2 bottom 551473

Stack height 23

5800 and 5900 series

small format

interchangeable core

top 664710 12 control 8816 866 master 4424 - 2 bottom 551473

5240-XX-1206 Yale and

5340-XX-1206 Medeco

top 99710 13 15

control 8816 866 master 4424 - 2 bottom 551473

5140-XX-1206

Corbin Russwin large format

interchangeable core

top 99710 13 15 control 8816 866 master 4424 - 2 bottom 551473

Key Cutting & Pinning

Section 3 - 18

A2 System Small Format Interchangeable Core Pinning Charts

Control 960478

TMK 528614

742836 304052 186290

60478

SOP abcde f

#4 top pin makes stack total 23.

#12 buildup pin makes stack height 19 for control.

#2 master pin makes #7 cut of change key work.

2 5

#5 bottom pin for #5 cut of TMK

change key cut is 7

top

4713 965

pins

12 12 2614 12

226222

742836

A small format interchangeable core pinning chart is an expanded key bitting array (KBA) that speeds pinning. At the left is a key bitting array. The control combination is a change key that is set aside. SOP stands for Sequence of Progression.

The inset at the left shows the pin stack for the first change key possibility in the first chamber.

The "7" from the KBA is in the large oval. To the right of the oval are the pins needed to make the #7 cut work with the #5 cut of the top master key and the #9 cut of the control key. Pin stacks are read from the bottom up.

The complete pinning chart contains every possible pin stack for every possible change key and master key in the system.

522614

To pin a core to a given key, find the bitting of the key in each position in the large oval

14 14 2812 14

224642

304052

304012

14 828814

Key Cutting & Pinning

462484

186290

126210

10 10 2810 10

448264

960478

and install the pins indicated in the squares next to the oval.

The bottom row beneath the heading "complete pin stacks for constants", gives complete pin stacks, including top pins, for the rotating constant method, or for pinning to master keys only.

Factory bitting lists come with pinning charts. To make a pinning chart, fill in the large ovals with the cuts in the key bitting array, and do the pin stack calculations one column at a time.

520414

complete pin stacks for constants

4713 965

14 14 2816 14

528614

SKD's and cross keying

SKD's and cross keying cannot be pinned from this chart. SKD's are never master keyed. Cross keying must be calculated separately for each keying specification.

528614

Section 3 - 19

Calculating Small Format Interchangeable Cores A4 Pinning Stacks

A4 system has six depths numbered 0 to 5, shallow to deep, respectively. This is a single step progression system. Because there is no parity in the A4 system, key interchange between systems in the same keyway

cannot be prevented.

The operating and control shear lines are distinct. All the operating keys work at the operating (plug) shear line. Only the control key works at the control shear line.

Pin to the operating keys first. The shallow cut determines the bottom pin. A master pin makes up the difference between shallow and deep operating cuts. The numerical value of the bottom pin and master pin together is called the "plug total." For example, a #1 bottom pin plus a #4 master pin results in a plug total of

Buildup pins are added to the plug total to make the control key operate at the control shear line. Top pins are added to achieve a uniform pin stack height of 14 in all chambers.

The control dimension, or thickness of the control lug, is a multiple of the increment. The increment is 0.021" while the control dimension is 0.21". Because the control lug is 6 increment units thick, the control shear line is 6 units higher than the operating shear line.

add top pin to

Calculating the pin stack

make a stack

total of 14

3. Add a top pin to bring the total pin stack to 14.

2. Add 6 to control bitting. Subtract plug total. The remainder is the buildup pin.

1. Pin operating keys to the plug shear line. The plug total equals the deep operating bitting.

buildup pin equals control cut + 6 minus plug total

master pin equals the deep operating cut minus the shallow cut

bottom pin equals the shallow operating cut

plug total

Key Cutting & Pinning

Section 3 - 20

Calculating Other A4 Pinning Stacks

omparing A4 Pin Stacks

he examples on this page show pinning for

T key symbol 1AA.

When pinning conventional cylinders, ignore the control bitting. If a top pin of 12 or greater is needed, use two pins of equal length to bring the pin stack to the required height. When an odd numbered top pin is required, such as 15, use two pins that are close in size – 8 and 7 instead of 11 and 4.

For the patent pin chamber in all conventional cylinders, insert the proper bottom and top patent pins, then insert a number 4F top pin.

Pinning for all Peaks products can now be accomplished with only one spring. That stainless steel spring is number 3800-00-4010

control CTR 153042 master AA 204153 change 1AA 315103

Stack height 18

Stack height 15

5400-XX-1206

Key in Knob

top 6710 7 10 6

buildup 67-7-6

master 111 - 5bottom 204103

5400-XX-1299

"99" and "95" Key-in-Knob

top 6710 7 10 6

buildup 67-7-6

master 111 - 5bottom 204103

5401-XX-1210 Rim / Mortise

top 786867

buildup 897978

master 111 - 5bottom 204103

top 846957 control 4 10 4555 master 111 - 5-

5240-XX-1206 Yale and

5340-XX-1206 Medeco

bottom 204103

Key Cutting & Pinning

Stack height 14

5800 and 5900

series small format

interchangeable core

top 735846 control 4 10 4555 master 111 - 5bottom 204103

format interchangeable core

top 846957 control 4 10 4555 master 111 - 5bottom 204103

5140-XX-1206

Corbin Russwin large

Section 3 - 21

A4 Keying is not available for the

5440 series cylinders

A4 System Small Format Interchangeable Core Pinning Chart

small format interchangeable core pinning chart is an expanded

Control 153042

MK 204153

315204 420315 531420

42531

0 153042

SOP abcde f

#7 top pin makes stack total 14

#4 buildup pin makes stack height 7 for control.

#1 master pin makes #3 cut of change key work.

1 2

#2 bottom pin for #2 cut of TMK

change key cut is 3

pins

735846

4 10 4454

111151

315204

204103

395353

224242

420315

200113

285255

333333

531420

201120

A key bitting array (KBA) that speeds pinning. At the left is a key bitting array. The control combination is merely a change key that has been set aside.

The inset at the left shows the pin stack for the first change key possibility in the first chamber.

The "3" from the KBA is in the large oval. To the right of the oval are the pins needed to make the #3 cut work with the #2 cut of the top master key and the #1 cut of the control key. Pin stacks are read from the bottom up.

The complete pinning chart contains every possible pin stack for every possible change key and master key in the system.

To pin a core to a given key, find the bitting of the key in each position in the large oval and install the pins indicated in the squares next to the oval.

The bottom row beneath the heading "complete pin stacks for constants", gives complete pin stacks, including top pins, for the rotating constant method, or for pinning to master keys only.

575155

242422

042531

002131

565555

151111

153042

103042

complete pin stacks for constants

735846

5 11 5555

204153

Factory bitting lists come with pinning charts.

SKD's and cross keying

SKD's and cross keying cannot from this chart. SKD's are never master keyed. Cross keying must be calculated separately for each specification.

be pinned

Section 3 - 22

Key Cutting & Pinning

Peaks®Global

Notes

Key Cutting & Pinning

Section 3 - 23

Technical Manual Section 4: Key Control & Record Keeping

Introduction

Peaks Global contracts specify that:

) The key blank identification number may not be removed, stamped-over, or altered in any way;

2) Dealers can only duplicate keys bearing their own blank ID number, and must refuse to copy others;

3) Only cut keys may be sold; key blanks may not be sold, lent or given away;

4) Proper key records must be kept and authorization procedures observed.

Poor record keeping can be a serious liability. Overall, end users respond favorably to professional record keeping practices when they understand that they exist for their protection.

Authorized Signature Card

The authorized signature card records the key system's physical location and signature specimens of the persons authorized to order locks and keys from Kaba.

A completed signature card is required to initiate any factory key system. It registers the system to a specific dealer and is used to verify signatures on original letters of authorization when subsequent orders are placed. Below is a sample of a properly completed signature card.

Key Control & Record Keeping

Dealer Systems – Authorization Procedures

Tom Jones

TYPE NAME TYPE NAME OF DEALER

Tom Jones

Signature

John Doe

TYPE NAME

John Doe

Signature

Ann Smith

TYPE NAME

This card is the only document establishing who is authorized to purchase additional PEAKS® or GEMINI® cut keys and locks of specific assigned codes. Any changes,

dditions or deletions of signatures must be submitted on company letterhead signed

a by one of the current authorized signatories. Only a person currently on the signature card can add or delete signatories.

Ann Smith

Signature

0001-10-8087

AA Locksmiths

1 Main Street

TREET ADDRESS

Anywhere, NC 27105

CITY STATE ZIP

Authorized Signature(s)

Kaba Access Control 2941 Indiana Ave Winston-Salem, NC 27105

Always meet the minimum requirements for authorization on a Peaks system:

1) Know who the end user is.

2) Know who has authority to order more locks or keys.

3) Be able to prove that you have furnished locks and keys only to authorized persons.

Authorization procedures for ordering Peaks keys and locks should be uniform and simple. Here are several suggestions for procedures:

1. Obtain signed purchase orders or letters of authorization for all Peaks locks and keys. Check the signature on the purchase order or letter against the signature card on file.

2. Design your own form and obtain signatures upon receipt of Peaks locks and keys. The signature card on file is used to confirm the identities of persons signing for materials.

3. Furnish customer Peaks Global cards to present as authorization, or to use with a letter for additional protection.

Section 4 - 1

Adding / Deleting Names on the Signature Card for Factory Key Systems

1. Current Signatories

Only a person currently on the signature card can add or delete others.

a. Transfer of Authority Letter

his is a letter written by the Dealer to change the signature card. It names the person(s) being added

T to or deleted from the signature card. It must be signed by someone currently on the signature card and submitted with signature samples for the person(s) being added. The following is a sample of such a letter.

Sample Letter

A Locksmith

January 1, 2005

Kaba Access Control 2941 Indiana Ave Winston-Salem, NC 27105

Gentlemen:

A 1 Main Street

Winston-Salem, NC 27105

A Transfer of Authority Letter must:

1) identify the system by Register number;

2) name the person or persons being added or deleted from the signature card;

3) be accompanied by signature samples of any persons added;

4) be signed by one of the current signatories.

I am on the signature card for Peaks Global system # P001. Please add Brad Kaszer and Stewart Levine to the list of authorized signatories, and remove my name.

Enclosed is a new signature card signed by Mr. Kaszer and Mr. Levine.

Sincerely,

It is very important to positively identify the key system by its Register Number.

John Doe

enc: signature card

2. No Current Signatories a. Declaration of Authority Letter

The declaration letter validates a new signature card when the original persons on the card are no longer available. It is written by the factory to protect both the dealer and the factory from fraudulent claims of authorization. Contact Kaba if this form is required. This letter is completed by the person claiming authority for the key system.

Key Control & Record Keeping

Section 4 - 2

Authorization Procedure

The Initial Order for a New Key System

Subsequent Orders against an Existing Key System

Factory Systems Require a Letter of Authorization

The letter of authorization, written and signed by an authorized signatory of the dealer, is required before the factory can start production. The letter authorizes the factory to furnish Peaks keys or cylinders as requested. The factory will not accept faxes or photocopies of these letters.

Letters of authorization can be written in two ways: 1) detailing the keys and cylinders to be ordered; or

2) referring to a separate, attached purchase order or list.

Here is an example of a detailed letter. This example refers to a separate order.

A Locksmith

January 1, 2005

Winston-Salem, NC 27105

Kaba Access Control 2941 Indiana Ave Winston-Salem, NC 27105

1 Main Street

January 1, 2005

Kaba Access Control 2941 Indiana Ave Winston-Salem, NC 27105

Winston-Salem, NC 27105

A Locksmith

Main Street

I am an authorized signatory for Peaks Global key system # P001. I authorize you to furnish:

200 Master Keys

Sincerely,

I am an authorized signatory for Kaba Peaks Global key system # P001. I authorize you to furnish the keys and cylinder on the attached order.

Sincerely,

John Doe

Please do not send another signature card to authorize a subsequent order. The signature card is used only once with the initial order to register the system.

Key Control & Record Keeping

Dealer written key systems

Dealers should follow the same authorization procedures as Kaba for adding and deleting names on the signature card.

enc: purchase order #621

Section 4 - 3

Writing the Key System Expansion Specification

Expansion information is essential for accurately planning a key system. Expansion should include the installed portion of the key system and planned future growth.

The key system expansion should be furnished in clear terms. For example, a three level system may be described as follows:

Furnish a new grand master key system. Plan for a top control key. Provide for eight master keys with up to forty changes each. Provide for twelve changes directly under the grand master.

Or,

1 Grand Master x 1 Control x 8 Masters x 40 Changes / Master plus 12 Grand Changes

Questions regarding the design and generation of key systems may be directed to Kaba Key Records Department.

Key Control & Record Keeping

Section 4 - 4

The Standard Key Coding System

The following key symbols are the lock industry standard, used by manufacturers, BHMA, DHI and ALOA. They should be used when specifying any master keyed system. The symbols are constructed as follows:

Abbreviation Key type Symbolized by Symbols or "keysets"

GGMK great grand master key GGM GGM GMK grand master key single letter A, B, C, T MK master key pair of letters AA, AB, CC, BA, TR CK change key letters and numbers AA1, AB29, 17AA, SKD1

One level of keying - the most secure keying

Locks are never master keyed, but keyed alike (KA) or keyed different (KD). If you have two cylinders keyed to SKD1, it is a keyed alike group.

SKD1 SKD2 SKD3 SKD4 SKD5 SKD6

Two levels of keying - simple master key system

Consists of a Master and change keys. Master key is named with an identical pair of letters, AA, BB, CC, etc. The change key numbers go in front of the letter pair.

1AA 2AA 3AA 4AA 5AA SKD1

Three levels of keying - grand master key system

Consists of a Grand Master and multiple Master keys under the Grand. Change key numbers go after the letter pair. The first letter of the master key symbols is the grand.

AA AB

Key Control & Record Keeping

AA1 AA2 AA3 A1 AB1 AB2 AB3 SKD1 SKD2

Four levels of keying - great grand master key system.

Consists of a Great Grand Master with multiple Grand Master "systems" under it. Change key numbers go after the letter pair.

GGM

AA AB BA BB

AA1 AA2 AA3 AB1 AB2 AB3 BA1 BA2 BA3 BB1 BB2 SKD1

Section 4 - 5

Special Symbols

Change keys directly under higher level master keys take the name of their associated master key and add numbers after the letter(s). SKD's, if used, are considered part of the system.

GGM CTR

AA BA

AA1 AA2 AA3 A1 BA1 BA2 BA3 B1 GGM1 SKD1

CTR is the symbol for a control key. A top control key, capable of operating all the cores in a system, is shown in the schematic at the same level as the top master key.

Cross keying

Although sometimes required, cross keying, either controlled or uncontrolled, should be discouraged. Cross keying greatly reduces the keying capacity of a system, severely limits the security of the cross keyed cylinder and makes the key system less flexible. Whenever possible, alternate solutions to cross keying should be explored.

If cross keying is required, each set's operating parameters need to be defined. The expressions can be written as follows: XAA1 oby AA1, AA2, AA, A (oby = operated by)

X1X oby AC1 - AC5, AC10, AC, A

In the second example above, the “X” after the cylinder designation indicates that there is no change key (CK). It should be noted that cross keying requirements need to be defined at the time bittings are being generated. Cross keyed cylinders are labeled with the “X” symbol.

Additional Details

The letter "X" should not be used to designate a grand master. As stated above, this letter symbol is reserved for use in cross keying.

The letters I and O should be avoided for use as grand master or master key symbols as they are sometimes confused for numbers. To avoid confusion with O, Q should also be avoided.

For systems with more than twenty-four master keys under a given grand, the counting numbers are used

between the letters of the pair. For example, A2A, A2B, A2C....A2Z are the symbols for master keys twenty-

five through forty-eight.

Key Control & Record Keeping

Section 4 - 6

SKD Combinations – Non-master Keyed Cylinders

SKD's Used in a Master Key System

The symbol SKD is used to indicate combinations in a master key system that are never operated by a

aster key. Typical uses are for securing personnel records, pharmacies, evidence rooms in police stations,

m etc., where SKD combinations provide greater security.

The key symbols SKD1, SKD2 and SKD3 represent different bittings. If you have three locks keyed to SKD1, you have a keyed alike group. It is for this reason that SKD does not mean single keyed different.

SKD sets are never master keyed; their combinations are derived outside of a master key system.

Non-master Keyed Cylinders - One Level of Keying

SKD is the standard symbol for one level of keying. Locks are either keyed-alike (KA) or keyed-different (KD). To prevent key interchange or repetition of SKD's, a bitting list can be generated under a selected parity pattern and the bittings crossed off the list as they are used.

Important Note:

Serious liability can arise by furnishing SKD's for different End Users under the same control key. Although this is convenient for servicing it is not an acceptable practice. Kaba treats SKD's under a single control key like a master key system. Such systems are registered by signature card to a specific Dealer.

Kaba Factory Bitting List Policy

A bitting list is a document showing all the key combinations used in a keying system. Possession of a bitting list imposes a serious responsibility for the integrity of the system. For these reasons, Kaba contracts designate the bitting list to be the property of the Dealer.

Since a bitting list requires the time and labor of a qualified professional to generate, a nominal fee will be charged for creating the list or for a transcript. This charge is in the factory price list.

Orders for bitting list transcripts are subject to the conditions of the specific key control contract and

Key Control & Record Keeping

distribution channel.

Section 4 - 7

Designing Top Master Keys and Control Keys

The standards given below are used by the factory in designing and generating bitting lists. They apply to

he top master key (TMK) in a system as well as the control key (CTR).

Design Standards

. TMK's should have at least one of the shallowest possible bittings in one progressed position, and one of

the deepest possible bittings in another position, whether it is progressed or not.

The purpose is to keep lower level keys from being cut down to the TMK or CTR bitting. The deepest possible cut statistically reduces key manipulation (key picking) as does a moderately deep constant.

2. Moderate cut-to-cut variations should be employed. Extremes in adjacent cut depths cause premature

wear in the cylinder and on the key. Bittings of this type should be assigned last.

3. Uniformly shallow or deep keys should not be used. For example, 988789, is easy to pick, and any key in

the system can be cut down to it. Uniformly shallow keys, like 120112, also make the locks easy to pick.

4. Declining step keys should be avoided. 976642 is an example of a declining step key. Such keys, when

worn, tend to pull out of a turned plug and make the cylinder less pick-resistant.

5. Deep cuts next to the bow should be avoided as they can weaken a key. Kaba recommends that this

position be progressed last in any key system to make all keys as strong as possible.

Control Keys (CTR)

The control key (CTR) should have the same characteristics as a top master key. The control key should normally differ from the top master key in all positions. The control key cuts are chosen from the progression columns of the KBA. The control is actually a change key. Note in the sample system that the key bitting array has been manipulated so that the control key is the last key in the system.

When you cross the control key combination off the progression list, you can be certain that no other key in the system will ever be a control key.

CTR 960478

TMK 528614

CTR 960478 742836 304052 186290

deepest shallowest 960478

SOP abcde f

TMK 528614

All systems should have different TMK's and distinct CTR combinations. TMK and control combinations should be recorded in a register to prevent repetition of the combinations. Kaba recommends that parity patterns be used to separate the master key systems from the KA and KD combinations for non-master keyed projects.

Key Control & Record Keeping

Section 4 - 8

The TMK Register

The TMK register logs all top master keys and control keys by system register number to prevent duplication of systems. This type of register is kept by all manufacturers. Kaba maintains their logs by keyway, parity pattern and system location.

Example of TMK Register

Mfr. Key Section TMK Control Parity Location Register # Corbin 60 453263 Sys70 Toledo A012 Dexter 67 12212 OEEOE Medina A102 Kaba PEAKS-D 836152 EOEOOE Parma A016 Kaba PEAKS-D 793063 957405 OOOEEO Bay Village A015 Kwikset 1063 41363 none Rocky River A035 Sargent LA 361794 363594 OEOOOE Bay Village A013

Adding small & large format interchangeable cores to a system of conventional cylinders

Small format interchangeable core / large format interchangeable core cylinders can usually be added to a system of 140 conventional cylinders at any time. KABA recommends that you write a control key for all Peaks systems, so that if small format interchangeable core / large format interchangeable core is added later, the control key will be properly designed.

Visual Key Control (VKC)

Visual key control is the marking of the face of cores and cylinders with the symbols of the standard key coding system. From a security standpoint this is not a wise practice. If a key is found, a glance at the face of the cylinder would reveal what the key operates.

Do not stamp the plug face. This voids the warranty and may collapse the patent pin chamber.

Key Control & Record Keeping

Concealed Key Control (CKC)

Concealed key control is the marking of key symbols on the side or back of cores or cylinders. Kaba marks the key symbol on the side of the core with a permanent marker. In this way, when the core is recombinated, the key symbol can be buffed off and no damage will be done.

Section 4 - 9

Technical Manual Section 5: Cylinder Installation Guide

Introduction

This is an aid to selecting Peaks Global key-in-knob cylinders for grade 1 and 2 cylindrical locksets. It should

e used in conjunction with Section 2 of the Peaks Global Technical Manual and your own library of competi-

b tors' catalogs and technical literature.

While there are many variations in trim designs, there is a finite offering of hardware. You will see the same

ew cylinder configurations used repeatedly.

The industry calls cylinders for both knob and lever trim "key-in-knob" cylinders. This document will use "handle" to mean the portion of the operating trim which contains the cylinder.

Key Demountable (KDH) versus Non-Key Demountable (Non-KDH) handles

To retrofit a cylindrical lock with Peaks Global, the handle must be removed to gain access to the cylinder. Some handles can be removed by turning an operating key and depressing a retainer.

Other locks require disassembly of the lockset and take more time to retrofit. This distinction is important when quoting labor for installation.

Tools

Basic hand tools are needed to service cylindrical locks, including standard and Phillips screw drivers, a plastic or rawhide mallet, and Superlube™ lubricant. Key demountable handles require a "poker" tool to depress the retainer. A1/16" pin punch is an excellent tool for this purpose.

Spanner wrenches are required for all grade 1 knobs, and a few grade 1 levers. Grade 2 knobs and levers are normally mounted with concealed screws and do not require spanner wrenches.

Any tools beyond basic hand tools required for specific hardware will be listed below.

Finishes

North American hardware finishes for the plug face of key-in-knob cylinders are as follow:

for white finishes such as 625, 626, 628, 629, and 630: use Peaks Global satin chrome finish number 25; for all other finishes: use Peaks Global satin brass finish number 04.

Cylinder Installation Guide

Section 5 - 1

Identifying the Manufacturer

The face of the latch is the first indicator of manufacturer. Certain brands of latch bolts and lock chassis are compatible. For example, occasionally an Arrow chassis will be seen with a Schlage latch bolt. When the knob or lever is removed, the

ppearance of the spindle cam, i.e., the cylindrical actuator into which the cylinder

a tailpiece fits, can be used to identify the chassis.

Logo

Brand On Face Notes

Arrow yes "AMEROCK"' and other OEM names have been used.

Corbin yes Prior to the brand merger in 1993, the individual brand names "CORBIN" or Russwin "RUSSWIN" were used. The Emhart logo, a capital E with horizontal arrows

was used during Emhart's ownership. Some older unit locks have no trademark.

Falcon yes Falcon LY series grade 1 levers were imported from the same

source as PDQ grade 1 levers and are sometimes confused.

LSDA yes Imported; house brand of the IDN companies.

Marks yes

PDQ maybe Latches for these locks bear check marks in a circle

and may be private labeled. Products assembled in the U.S.A. are marked "PDQ".

Sargent yes Product line numbers 6, 7, 8, 9, 10, 7600, etc. are stamped on the face.

eg., a latch face marked "8" indicates an 8 Line lock.

Schlage yes Same key-in-knob cylinder body used throughout cylindrical lock line.

Only the tailpiece shape and ori en ta tion vary.

Yale yes

5-pin versus 6-pin

Older hardware may have 5-pin cylinders and no room in the handle to retrofit a 6-pin cylinder. Existing operating keys can be misleading. For ex am ple, some contemporary hardware is pinned to 5-pin keys, even though the cylinders have six pin chambers. This is re ferred to as "drilled 6, pinned 5". Try a 6-pin key blank in the cylinder. It won't seat fully in a 5-pin cylinder.



(sic),

Cylinder Installation Guide

Section 5 - 2

Cylinder Removal Methods

Key demountable handle (KDH): Remove cylinder by turning any operating key, de press ing a retainer in the shank of the handle, and pulling on the handle.

Most contemporary cylindrical locks have key demountable handles.

1) Turn any operating key to the right about 45 degrees.

2) Depress the re tain er through the access hole in the trim, and pull off the knob.

Non-key demountable handle (Non-KDH): Remove cylinder by disassembling the lockset. Corbin Russwin and Sargent grade 1 knobs and preassembled locksets are the primary Non-KDH hardware.

brand grade 1 grade 1 grade 1 grade 2 grade 2

levers knobs preassembled levers knobs

Arrow KDH KDH KDH KDH

Corbin KDH Non-KDH Non-KDH KDH KDH/Non-KDH Russwin

Falcon KDH KDH KDH KDH KDH

LSDA KDH KDH KDH KDH

Marks KDH KDH KDH KDH

PDQ KDH KDH KDH KDH

Sargent KDH Non-KDH Non-KDH * KDH KDH

Cylinder Installation Guide

Schlage KDH KDH KDH KDH

Yale KDH KDH KDH KDH KDH

NOTES: *Sargent discontinued their unit lock decades ago. However, they also made a lock called the "IntegraLock" (7600 Line) that used a small mortise body with through-bolted key-in-knob trim.

Section 5 - 3

Arrow Architectural Hardware

Division of Assa Abloy

• "ARROW" appears on the latch face.

Basic hand tools required.

•

NOTES:

• Flexcore is available in small format interchangeable core only.

• Entire Arrow line is available prepped for small format interchangeable core.

Arrow H series J series L, M series M series tubular

grade 1 grade 2 grade 2 grade 2 deadlocks knobs & levers interconnected levers knobs

retrofit type KDH KDH KDH KDH

Peaks Global: 5400-xx-1099 5400-xx-1099 5400-xx-1099 5400-xx-1099 5400-xx-109

Corbin Russwin Architectural Hardware

Division of Yale Security Assa Abloy

• Depending on the vintage, "CORBIN", "CORBIN RUSSWIN", "EMHART", and "RUSSWIN" will all be seen on

latch faces.

• Corbin Russwin's proprietary profile core can be retrofit with Peaks 5140 Rcore.

Corbin Russwin Corbin old no. old no. Russwin (1993) product retrofit method

700 900 CL3200 grade 1 levers KDH 5140 large format interchangeable core

na na CL3300 grade 1 levers KDH 5400-xx-1099

800 800 CL3400, CL3600 grade 1 levers KDH 5400-xx-1099 or 5140 large format

na na CL3800 grade 2 levers KDH 5400-xx-1099 with OEM

discontinued 9-97 tailpiece (replaced by CL3900)

na na CL3900 grade 2 levers KDH 5400-xx-1055

400 400 CK4200 grade 1 knobs Non-KDH 5400-xx-1004 or 5140 large format

6600 3400 CK4400 grade 2 knobs, import KDH/Non-KDH in development 300 500 UT5200 grade 1 unit locks Non-KDH 5400-xx-1004 or 5140 large format

TOOLS:

• Grade 1 levers CL3400 and CL3600, require #585F48 hex wrench for flanged nut on rose liner.

• Grade 1 knobs, CK4200, require spanner wrench and long nose Tru-Arc pliers.

• Replacement of pre-1972 cylinders requires purchase of Corbin Russwin cylinder driver #144F29

Peaks Global

interchangeable core

Cylinder Installation Guide

Section 5 - 4

Corbin Russwin

Retrofitting Corbin Russwin CK4200 grade 1 knobs

current model, 1976 to date

Older locks do not have this plate.

1. Loosen inside rose with spanner wrench; depress knob retainer.

3. Depress outside knob retainer; remove outside knob. 4. Remove knob cap if present.

2. Remove inside trim; remove lock from door.

Cylinder Installation Guide

5. Remove ring with Tru-arc pliers; remove spindle and cylinder.

Section 5 - 5

5400-xx-1004

6. Install Peaks Global cylinder 5400-xx-1004 and reverse above steps.

Corbin Russwin

Retrofitting Corbin Russwin CK4200 grade 1 knobs

models prior to 1976

Locksets made prior to 1976 were made with the outside knob retainer rigid. To remove the outside knob on pre-1976 locksets, remove one of the chassis screws completely, and loosen the other screw slightly. This will allow the knob retainer to pivot out of the spindle and permit knob removal.

remove

outside knob

loosen

outside knob

pivot retainer out of spindle

older style outside knob has cap that must be pried off with a small screwdriver to reveal Tru-arc ring.

Cylinder Installation Guide

Section 5 - 6

Falcon Lock Co.

Division of Ingersoll Rand

• "FALCON" appears on the latch face

TOOLS:

Spanner wrench is required for grade 1.

•

/16" pin punch for depressing retainer

•

Falcon LY series X series RU and X series S series D series

grade 1 grade 1 grade 1 unit lock grade 2 tubular levers knobs preassembled knobs deadlocks/latches

retrofit type KDH KDH KDH KDH

Peaks Global: 5400-xx-1099 5400-xx-1099 5400-xx-1099; 5400-xx-1099 5400-xx-1095

• 5400-xx-1095 is identical to 5400-xx-1099, except for the small diameter plug face required for Falcon dead locks and old style X series unit locks.

Marks USA

Amityville, New York

• "MARKS" appears on the latch face.

• Grade 1 and 2 cylindrical locks can be prepped for small format interchangeable core.

• Current Marks deadbolts accept only 6-pin small format interchangeable core.

Marks 195/295 180 170/270 110/120 130 Deadlocks

grade 1 grade 1 grade 2 grade 2 levers knobs levers knobs

retrofit type KDH KDH KDH KDH

Cylinder Installation Guide

Peaks Global: 5400-xx-1099* 5400-xx-1099* 5400-xx-1099* 5400-xx-1099* 5400-xx-1099*

*with original Marks tailpieces

TOOLS:

• Marks spanner wrench (engages entire rose) is required to install lockset, but not to change cylinders.

hole in edge of rose

Section 5 - 7

knob

rose

Sargent

Div. of Assa Abloy

"SARGENT" appears on the latch face. Latch face bears a number indicating product line (6, 7, 8, 9, 10, etc.). Sargent 10 Line is identical to Arrow lever, except for small plug face diameter.

TOOLS: 7, 8 and 9 Line grade 1 knobs require a 3/32" hand held punch and mallet. 10 Line grade 1 levers require Sargent bushing wrench, #10-0022.

Sargent 6 line 6 Line 7, 8, 9 Line 10 Line 5500

grade 2 grade 2 grade 1 grade 1 grade 2

non-Ball knobs Ball knobs knobs levers knobs

retrofit type KDH KDH Non-KDH KDH KDH

Peaks Global: 5400-xx-1095 5400-xx-1095 5400-xx-1008 5400-xx-1095 5400-xx-1095

Sargent 6500 Line 2000 7600 Line tubular

grade 2 levers exit devices preassembled deadlocks

retrofit type KDH KDH Non-KDH

Peaks Global: 5400-xx-1095 5400-xx-1095 5400-xx-1076 5400-xx-1099

Cylinder Installation Guide

Section 5 - 8

Sargent

Retrofitting Sargent 7, 8 and 9 Line grade 1 knobs

1) With spanner wrench, loosen inside rose and unscrew outside rose com plete ly.

ose unscrewed

knob retainer spring visible through hole in aligner tube

aligner tube

2) Lock must be unlocked (outside knob free). If storeroom function, remove inside knob first per step 3. For other single cylinder functions, it is not necessary to remove inside knob.

3) Rotate knob and until knob retainer spring is visible in any hole threaded shank of aligner tube.

4) Depress knob retainer spring with small screw driv er. Pull out on knob and rotate back to rest position. Pull knob out of aligner tube.

6) Drive roll pin com plete ly into knob

5) Pry up nylon ring and remove knob collar.

with 3/32" punch and mallet.

Cylinder Installation Guide

7) Unscrew spindle from knob. Slowly separate knob and spindle. Observe order of parts and save them, including the roll pin.

8) Replace cylinder with Peaks Global 5400-xx-1008. Reverse steps to reassemble. Do not re as sem ble with key in cylinder.

Section 5 - 9

Schlage Lock Co.

ivision of Ingersoll Rand

• "SCHLAGE" appears the latch face.

TOOLS:

• Spanner wrench is required for grade 1.

• Castlenut bushing wrench (included with new locks) is required to install AL grade 2 leversets, but not to change the cyl in ders.

/16" pin punch for depressing retainer

•

NOTES:

• Original S series tailpiece must be used in 5400-xx-1099 cylinder.

Schlage D series H series A, AL series S series E/B series

retrofit type KDH KDH KDH KDH

grade 1 grade 2 grade 2 grade 2 tubular knobs & levers interconnected knobs & levers levers deadlocks/latches

Peaks Global: 5400-xx-1099 5400-xx-1099 5400-xx-1099 5400-xx-1099 5400-xx-1099

Yale Security

Assa Abloy

• "YALE" appears the latch face.

• All grade 1 & 2 product is key demountable.*

TOOLS:

• 5400 grade 1 knobs require a spanner wrench.

• 5400L grade 1 levers require an 1/8" Allen wrench and an original Yale 5400L spanner wrench.

Yale 5400L 5400 6200 Monolock 5300L 5300

retrofit type KDH* KDH KDH KDH KDH

Peaks Global: 5400-xx-1055 5400-xx-1054 5400-xx-1054 5400-xx-1095 5400-xx-1054

grade 1 grade 1 grade 1 unit lock grade 2 grade 2 levers knobs preassembled levers knobs

*The original 5400 Augusta Lever was non-key demountable. This lock was pro duced for only a few months and was re de signed to be key demountable.

Cylinder Installation Guide

Section 5 - 10

Peaks®Global

Notes

Cylinder Installation Guide

Section 5 - 11

Peaks®Global

Notes

Cylinder Installation Guide

Section 5 - 12

Kaba Access Control

2941 Indiana Avenue Winston-Salem, NC 27105 U.S.A. Tel.: 800 849 8324 or 336 725 1331 Fax: 800 346 9640 or 336 725 3269

KAA1134 02 09

Kaba 5402 Series, 5401 Series, 5400 Series, 5140 Series, 5900 Series Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual