Abus Vitess Rim User manual

1
Vitess™ High Security
Service Manual
ABUS | USA LLC
www.abus.com

2
TABLE OF CONTENTS
About Vitess™ ................................................................................. 4
Terminology and Formats of Delivery.................................................... 5
Rim Cylinders .................................................................................. 6
Mortise Cylinders ............................................................................. 7
Key-N-Knob/Lever Cylinders................................................................8
Deadbolts.......................................................................................8
83 Series Cylinder............................................................................. 9
Key Bitting Specification ...................................................................10
Calculation Rules ............................................................................ 11
Master Key System Management......................................................... 11
Assembly Instructions - Rim .............................................................. 12
Assembly Instructions - Mortise.......................................................... 13
Assembly Instructions - KNK/KIL.......................................................... 14
Assembly Instructions - 83 Insert ........................................................ 15
Special Pin Instructions - KNK/KIL and 83 Insert .....................................16
Refill of Housings............................................................................ 17
Notes ...........................................................................................18

3
LOCKING SYSTEMS
ABUS PFAFFENHAIN™
OUR STANDARD: QUALITY
High-quality raw materials, highly skilled staff and consistent development and manufacture of our locking cylinders
from start to finish in Germany guarantee you the highest quality and a long product life. For us, quality means
discipline, teamwork and continuously striving to make improvements in all business areas. We impress our customers
with first-class products, expert advice, easily accessible service, fast processing times and a strong representation of
our services in the market.
ABUS PFAFFENHAIN™
ABUS Pfaffenhain™ is part of the international ABUS group and specializes in mechanical locking systems. The company
has over 70 years of experience in the development and manufacturing of high-quality security products. The locking
systems are constructed and manufactured in Germany, ensuring that consumers receive precision products that
maintain their high level of performance after many years.
LOCKING SYSTEMS FOR BUILDING SECURITY
A locking system is a decisive element in ensuring a building has the highest levels of security, comfort and exibility.
It regulates who has access to a building, and species each person‘s access rights. ABUS doesn‘t oer an o-the-peg
solution, but rather a complete, well-designed modular system. This means you can select the exact equipment you
need.
QUALITY MADE IN GERMANY
ABUS locking systems are manufactured under consistent conditions in Germany – from the cylinder housing to the core
pins – and they guarantee both private and industrial users the highest level of protection against manipulation of
the locking cylinder and illegal key copying. This is ensured primarily by using patented technologies and high-quality,
precision products with the “Made in Germany” stamp of quality.

4
VITESS™ LOCKING SYSTEM
• When patent is granted, patented key
control through 2034
• Trademark Intop System restricts
unauthorized key duplication even aer
patent expires
• Available in Mortise, Rim, Key-in-Knob/Lever,
Deadbolt and 83 Series™ Locking Insert
HIGHLIGHTS OF VITESS™
TECHNICAL DETAILS
• Patent pending
• 6 locking elements
• 14mm (0.55“) core diamter
ABUS LOCKING SYSTEMS
ABUS locking systems are ideal for programs of various sizes, from small to large
master key systems. The range covers keyed alike cylinders, small and medium
master key systems, as well as large grand master key systems. If requested, the
planning and calculation of the grand master key system can be done by ABUS
Pfaenhain™.
All cylinders of ABUS Pfaenhain™ have a core diameter of 14mm (0.55“). This
increased diameter enables a very large number of combinations inside of the
cylinder, making very large and complex grand master key systems with ABUS
possible. These locking systems oer 1.5 million true key diers!
STRONG DRILL PROTECTION
• ABUS locking systems oer superior drilling protection
compared to competitors
• 4 additional hardened steel pins are inserted into the
cylinder (two per cylinder core and housing) and an additional carbide pin is inserted into the front
of both housing sides
GRAND MASTER KEY SYSTEMS WITH A GUARANTEED SUPPLY FOR THE
NEXT 20 YEARS
A grand master key system is a long-lasting investment in security. ABUS guarantees to supply needed
cylinders or single parts up to 20 years aer the creation of the grand master key system. Of course, the
system can also be extended - mechanically or electronically - at any time. For this ABUS plans 20%
extension reserve in advance.
ABUS LOCKING SYSTEMS
14mm

Patented
until 2034*
Trademark
Protection
Standard drill protection -
pins made of hardenend steel
6 locking elements
Intop System
Paracentric
precision
profile
Key cuts Intop System
Intop
System
*Patent pending, max. patent term 2034

5
Key blanks always include
InTop cut on first position
(only available for level 2, 3,
4, 5)
Cut keys always include InTop
cut on first position and
further cuts
Pre-load housing + uncombinated core + key blanks
(only available for level 2, 3, 4, 5)
TERMINOLOGY
Vitess™ Terms
Throughout this manual, we use specific terms to define the components of the Vitess™ program. Images and
descriptions of these terms are provided below. As a sample we have chosen a KnK/KiL cylinder, but the concept of
formats is similar for Rim, Mortise etc.
Parts
Top springs, top pins
(hardened steel pins,
mushroom pins, center pins)
Empty housing (not for sale)
Pre-Load Housings
Housing + top springs + top pins + accessories
(only available for level 2, 3, 4, 5)
Uncombinated Core
Core without bottom pins
(only available for level 2, 3, 4, 5)
Uncombinated Cylinder
Combinated Cylinder
Combinated (bitted) cylinder includes everything
Ready to go. Available KD/KA/MK
(available for level 1, 2, 3, 4, 5)
Key Blanks/Cut Keys

6
CONVENTIONAL RIM CYLINDERS
Item HD - Head Diameter HT - Head Thickness BL - Body Length w/cam BD - Body Diameter
Rim Cylinder 1.337” (33.95mm) 0.118” (3mm) 1.075” (27.3mm) 1.146” (29.1mm)

HD: Head Diameter
HT: Head Thickness
BL: Body Length
BD: Body Diameter

7
CONVENTIONAL MORTISE CYLINDERS
Item HD - Head Diameter HT - Head Thickness BL - Body Length w/cam BD - Body Diameter
1-1/8” Mortise Cylinder 1.370” (34.8mm) 0.138” (3.5mm) 1.042” (26.47mm) 1.150” (29.2mm)
1-1/4” Mortise Cylinder 1.370” (34.8mm) 0.138” (3.5mm) 1.200” (30.47mm) 1.150” (29.2mm)

HD: Head Diameter
HT: Head Thickness
BL: Body Length
BD: Body Diameter
Cams for Conventional Mortise Cylinders
Order Code SZ01 SZ06 SZ09 SZ11 SZ12
Description Mortise Cam
(Adams Rite®)
Mortise Cam
(Schlage®L)
Mortise Cam
(Sargent®)
Mortise Cam
(Corbin Russwin®)
Mortise Cam
(Yale®)

8

Item BL - Bible
Length
CD - Cylinder
Diameter
CH - Cylinder
Height
CL - Cylinder
length

Length
FL - Front
Length
PD - Plug Face
Diameter
KiK/KIL Cylinder 1.024” (26mm) 0.634” (16.1mm) 1.039” (26.4mm) *see below 1.290” (32.76mm) 0.110” (2.8mm) 0.622” (15.8mm)
Tailpieces (*Cylinder length depends on tailpiece) STD KF03 KF01 KS03
Cylinder Length 2.15" (54.66mm) 3.62“ (91.91mm) 2.07” (52.66mm) 2.21” (56.06mm)

BL: Bible Length
CD: Cylinder Diameter
CH: Cylinder Height
CL: Cylinder Length
EL: Eective Length
FL: Front Length
PD: Plug Face Diameter

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Tailpiece Tailpiece
83 SERIES™ CYLINDER INSERT
Item BL - Bible
Length
CD - Cylinder
Diameter
CH - Cylinder
Height
CL - Cylinder
length

Length
FL - Front
Length
PD - Plug Face
Diameter
83 Insert 1.283” (32.6mm) 0.632” (16.05mm) 1.053” (26.75mm) 1.526” (38.75mm) 1.490” (37.85mm) 0.035” (0.9mm) 0.587” (14.9mm)

BL: Bible Length
CD: Cylinder Diameter
CH: Cylinder Height
CL: Cylinder Length
EL: Eective Length
FL: Front Length
PD: Plug Face Diameter

10
KEY BITTING SPECIFICATION
Root
Depths
mm inch
94.55 0.1791
84.90 0.1929
75.25 0.2067
65.60 0.2205
55.95 0.2343
46.30 0.2480
36.65 0.2618
27.00 0.2756
17.35 0.2894
07.70 0.3031
X8.05 0.3169
Y8.40 0.3307
Z8.75 0.3445
Top
Pins
mm inch
99.23 0.3634
88.88 0.3496
78.53 0.3358
68.18 0.3220
57.83 0.3083
47.4 8 0.2945
37.13 0.2807
26.78 0.2669
16.43 0.2531
06.08 0.2394
X5.73 0.2256
Y5.38 0.2118
Z5.03 0.1980
Master
Wafer
mm inch
13 4.55 0.179
12 4.20 0.165
11 3.85 0.152
10 3.50 0.138
93.15 0.124
82.80 0.110
72.45 0.096
62.10 0.083
51.75 0.069
41.40 0.055
31.05 0.041
20.70 0.041
Cut
Distance
mm inch
13.75 0.148
27.55 0.297
311.30 0.445
415.05 0.593
518.80 0.740
622.55 0.888

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CALCULATION RULES
Recommended according to German standards.
• When using one key-way for KD/KA and MKS calculate with 2-step-progression (code groups, even, odd)
• Maximum repeated depths/cuts per key: 3
525226 525525
• Maximum consecutive repeated depths/cuts per key: 2
535226 533342
• No stair-step depths/cuts
543210
• At least 1 minimum jump of 4 steps
546243 543454

• First chamber is fixed: Intop pin no. 5
• No master pins on chamber 1
• 2nd pin can only “jump“ 4 heights upwards or downwards.
513624 503624
• Remaining chambers max jump is 6
517174 518184
• Due to the profile check pin we recommend not to use master pins no. 2 (only 4 or larger), however 2 can be used
in case of “emergency” (no more codes available)
MASTER KEY SYSTEM MANAGEMENT
2-Step Progression (Even/Odd)
• 2-step progression allows us to manage all codes/pins/cuts that our system can use
to generate codes for our master key systems or simply KD/KA cylinders; this way no
keys would be repeated
• Odd/even codes management: B = odd A = even
• 6 pins generate 64 groups (Even/Odd) from AAAAAA to BBBBBB
• Depending on the size/complexity one group might be used for more then just one
master key system
Even A Odd B
Z
Y
X
0
1
2
3
4
5
6
7
8
9

12
Step 2
• Insert the hardened InTop pin into the 1st
chamber
• Attention: Pull the key a little and insert
it again
Step 4
• Position the pinned core with the
inserted cut key and rotate the core to
the 2 o’clock position

Delivery of the pre-loaded housing
• Our pre-loaded housing includes all parts that are necessary to
assemble a functional cylinder
• Inside the cylinder there is a black plastic plug which has to be
exchanged by a pinned core
• The housing is filled corresponding to the factory standard with
steel springs and housing pins
• Additionally the following parts are included: tailpiece, core
retaining clip
Step 1
• Insert the cut key into the cylinder core
• Place the profile check pin in the core
Step 3
• Insert the bottom pins made of hardened
steel into the 3rd chamber
• Insert the bottom pins made of nickel silver
into the 2nd and 4th to 6th chamber
Only for master keyed systems: Insert master
wafers
• Check with cut key – no pin should be
positioned too low or above the shear line
of the core – control with assembly tool
possible
Step 5
• Push the core inside until the plastic
plug has been pushed through
completely
• Rotate the core forward clockwise until
the key is at the 12 o’clock position
Step 6
• Remove the key by holding the core with
your thumb
• The core isn’t fixed yet and could be
pulled out with key inside
Step 7
• Insert the tailpiece into the core and
push on the core retaining clip

13

Step 2
• Insert the hardened InTop pin into the 1st
chamber
• Attention: Pull the key a little and insert
it again
Step 5
• Position the pinned core with the inserted
cut key and rotate the core to the 2 o’clock
position
Delivery of the pre-loaded housing
• Our pre-loaded housing includes all parts that are necessary to
assemble a functional cylinder
• Inside the cylinder there is a black plastic plug which has to be
exchanged by a pinned core
• The housing is filled corresponding to the factory standard with
steel springs and housing pins
• When ordered, additionally the following parts are included:
cam, screws
Step 1
• Insert the cut key into the cylinder core
• Place the profile check pin in the core
Step 3
• Insert the bottom pins made of hardened
steel into the 3rd chamber
• Insert the bottom pins made of nickel silver
into the 2nd and 4th to 6th chamber
Only for master keyed systems: Insert master
wafers
• Check with cut key – no pin should be
positioned too low or above the shear line
of the core – control with assembly tool
possible
Step 6
• Push the core inside until the plastic plug
has been pushed through completely.
• Rotate the core forward clockwise until the
key is at the 12 o’clock position
Step 8
• Fix the cam with 2 screws on the backside
of the core
Step 7
• Remove the key by holding the core with
your thumb
• The core isn’t fixed yet and could be pulled
out with key inside
Step 4
• 1 ¼ mortise cylinder: Remove the key
slowly from the core and stick extension
piece onto the t-groove

14
Step 2
• Insert the hardened InTop pin into the 1st
chamber
• Attention: Pull the key a little and insert
it again
Step 4
• Position the pinned core with the inserted
cut key and rotate the core to the 2 o’clock
position

Delivery of the pre-loaded housing
• Our pre-loaded housing includes all parts that are necessary to
assemble a functional cylinder. Inside the cylinder there is a
black plastic plug which has to be exchanged by a pinned core.
• The housing is filled corresponding to the factory standard with
steel springs and housing pin
• In addition, the following parts are included: tailpiece package,
screw cap, tappet and spring
Step 1
• Insert the cut key into the cylinder core
• Place the profile check pin in the core
Step 3
• Insert the bottom pins made of hardened
steel into the 3rd chamber
• Insert the bottom pins made of nickel silver
into the 2nd and 4th to 6th chamber
Only for master keyed systems: Insert master
wafers
• Check with cut key – no pin should be
positioned too low or above the shear line
of the core – control with assembly tool
possible
Step 5
• Push the core inside until the plastic plug
has been pushed through completely.
• Rotate the core forward clockwise until the
key is at the 12 o’clock position
Step 6
• Remove the key by holding the core with
your thumb
• The core isn’t fixed yet and could be pulled
out with key inside
Step 7
• Insert the spring and the tappet into
the drill hole on the backside of the
core (flat side of the tappet goes
into the core)
Step 8
• Push the tappet down and insert
the tailpiece and screw together
with screw cap on the backside
of the core

15
Delivery of the pre-loaded housing
• Our pre-loaded housing includes all parts that are necessary to
assemble a functional cylinder. Inside the cylinder there is a
black plastic plug which has to be exchanged by a pinned core.
• The housing is filled corresponding to the factory standard with
steel springs and housing pin.
• In addition, the following parts are included: core retaining
clip, washer, tailpiece and screw.
Step 2
• Insert the hardened InTop pin into the 1st
chamber
• Attention: Pull the key a little and insert
it again
Step 4
• Position the pinned core with the inserted
cut key and rotate the core to the 2 o’clock
position

Step 1
• Insert the cut key into the cylinder core
• Place the profile check pin in the core
Step 3
• Insert the bottom pins made of hardened
steel into the 3rd chamber
• Insert the bottom pins made of nickel silver
into the 2nd and 4th to 6th chamber
Only for master keyed systems: Insert master
wafers
• Check with cut key – no pin should be
positioned too low or above the shear line
of the core – control with assembly tool
possible
Step 5
• Push the core inside until the plastic plug
has been pushed through completely
• Rotate the core forward clockwise until the
key is at the 12 o’clock position
Step 6
• Remove the key by holding the core with
your thumb
• The core isn’t fixed yet and could be pulled
out with key inside
Step 7
• Fix the protruding side of the tailpiece into
the cutout on the cylinder housing
Step 8
• Add the washer to the back of the cylinder
core and fasten the retaining clip

16

Attention: If your pin
cut is a 9 in the 3rd,
5th or 6th chamber the
top pins need to be
changed according to
the following table:

Attention: If your pin
cut is an 8 or 9 in
the 3rd, 5th or 6th
chamber the top pins
need to be changed
according to the
following table:
Pin/Cut 1 (intop) 2 3 4 5 6 <- Pin
Chamber
Z
10609 10608 10609 10608 10610 10610
Standard
Top Pins
Y
X
0
1
2
3
4
5
6
Special Top
Pins
7
8
910611 10612 10612
Pin/Cut 1 (intop) 2 3 4 5 6 <- Pin
Chamber
Z
10609 10608 10609 10608 10610 10610
Standard
Top Pins
Y
X
0
1
2
3
4
5
6
Special Top
Pins
7
8
910611 10612 10612
Fixed Chamber
Fixed Chamber

17
• Insert the top pins
• 1st and 3rd chamber: hardened steel;
• 2nd and 4th chamber: anti-pick mushroom pins
• 5th and 6th chamber: stainless steel “centering” pins
Step 1
• Insert the springs, introduce the
s-shaped lever from below into the slot
of the charging thorn and push the
springs with the lever into the thorn
REFILL OF HOUSINGS
Step 2
• Insert the charging thorn into the
housing and remove the lever
Step 4
• Insert the lever from above into the slot
and push the pins completely into the
housing
1st 2nd 3rd 4th 5th 6th
Top-Pin: Hardened Mushroom: Brass Top-Pin: Hardened Mushroom: Brass Top-Pin: Nickel Silver Top-Pin: Nickel Silver
Step 5
• Turn the charging device with the lever
about 45° and remove the lever
• Push the plastic plug or follower into
the housing until the thorn has been
pushed through completely
Step 3
• Turn the thorn until the springs drop
audibly into the cylinder housing
Step 6
• Make sure the plug goes into the
housing with about an angle of 15°.
Housing pins should not be «snap» into
the groove of plug

18
NOTES

19
Proven: Globally
and in every dimension
Magdeburg Campus Tower,
Germany
© Architecture Groupe 6, 2010
Burj Al Arab, UAE
Collège Paul Langevin,
France
Centre Hospitalier Universitaire,
France
Herdecke Power Station,
Germany
Donauwörth Volkshochschule,
Germany
Ozeaneum, Germany
German Clock Museum,
Germany
Elbe Oce, Germany
Al Zeina, UAE
Emirates Palace Hotel, UAE
German Aerospace Centre,
Germany

Contact:
ABUS | USA LLC
23910 N. 19th Avenue, #56
Phoenix, AZ 85085
Phone: [phone]
Fax: [phone]
Email: vitesscustomerservic[email protected]
Internet: www.abus.com
08/16 HS Service Man
Part 95573
0 78217 95573 4
© 2016 ABUS USA LLC. All rights reserved.