Ingersoll-Rand SCHLAGE Everest User manual

Everest©Full Size Cylinder
Service Manual

i
Conventional Cylinders
Service Manual
Contents
Introduction...................................................................................................................................................................1
Key Control ...................................................................................................................................................................2
Open Keyways ..............................................................................................................................................................2
Restricted Keyways......................................................................................................................................................2
Primus®Integration ....................................................................................................................................................2
Mechanical Overview ...................................................................................................................................................3
Traditional Cylinder .......................................................................................................................................................3
Modular Cylinder...........................................................................................................................................................3
Traditional Cams ...........................................................................................................................................................3
Modular Cams...............................................................................................................................................................3
Modular Cylinders ........................................................................................................................................................4
Key-In-Knob to Modular Mortise and Rim Cylinder Conversion....................................................................................4
Modular Housing Interchangeability..............................................................................................................................4
Rekeying When You Have the Old Key (no master keying).......................................................................................5
Master Keying ...............................................................................................................................................................5
Rekeying When You Have No Keys .............................................................................................................................6
Key Bitting Specifications ...........................................................................................................................................7
Pins and Springs ..........................................................................................................................................................7
Cutting Everest™ Keys on the Blue Punch ...............................................................................................................8
Upgrading to New Top Jaw ..........................................................................................................................................9
Red Knob Operation .....................................................................................................................................................9
Black Lever Operation...................................................................................................................................................9
Upgrade Package 40-074 .............................................................................................................................................9
Upgrading Machines With a Red Knob.........................................................................................................................9
Upgrading Machines With a Black Lever ......................................................................................................................9
Tips for Cutting Everest™ Keys................................................................................................................................10
Key Blanks ..................................................................................................................................................................11
Operating Keys ...........................................................................................................................................................11
Control Keys................................................................................................................................................................11
Cut Keys......................................................................................................................................................................11
C Family Open Keyways .............................................................................................................................................11

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Conventional Cylinders
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Conventional Cylinders
Service Manual
Introduction
Everest™ is the name given to a new family of patented
key products by Schlage. Everest products are
distinguished by the patented undercut groove
milled into the right side of the key blade.
Patented
Undercut
Groove
The first product in this family was the small format inter-
changeable core (SFIC) introduced in November 1998 to
retrofit 7-pin Best®style IC products. A different service
manual (MS-C75) is devoted to SFIC.
This manual covers the Schlage Everest cylinder, which
is available in mortise, rim, key-in-knob and key-in-
lever versions. The Everest cylinder is also available in
Schlage’s 23-030 full size interchangeable core.
Except for the keyway and special pin which checks for
the lip on the side of the key section, Everest cylinders
are virtually identical to Schlage Classic™ cylinders with
the C keyway, which have been around since 1935.
Locksmiths and users get the benefits of the new patent
without the need to invest in new pin kits, key machines
or additional service equipment. However, a new top vise
jaw is needed for the Blue Punch to hold all Everest C
Family open key sections. A separate section of this
manual provides details on how to upgrade the old
Blue Punch.
Note: D Family restricted keys can be cut on a different
key bitting punch (40-099) because the top of the key
blade is not straight.
Larger Key Bow
PAT. 5,715,717
Undercut Groove Keyway and Everest Logo
on Plug Face
Hole in Cylinder Shell for Check Pin

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Conventional Cylinders
Service Manual
Key Control
Since the late 1960’s patents on keys have been used
primarily to prevent unauthorized key duplication. This is
the case with Schlage’s new Everest™ D Family key-
ways but the C Family open keyways are a major depar-
ture from this tradition.
Open Keyways
Everest C Family Keyways are protected by U.S. utility
patents 5,715,717 and 5,809,816 against unauthorized
manufacture and distribution. However, the C Family
keyways are readily available to the end user for fast and
easy key duplication without any formalities. All C key-
ways are considered “open” keyways which means they
can be stocked and sold by all locksmiths and
contract hardware dealers.
The purpose of the Everest C keyways is to guarantee
the end-user genuine Schlage quality replacement keys
and to provide commercial locksmiths and contract hard-
ware dealers a group of keyways not available in home
centers or retail key stands.
Everest C Family keyways are the default keyways for
new Schlage master key systems.
Restricted Keyways
For end-users who want restricted keys with patent
protection, Schlage offers its Everest D Family keyways.
Everest D Family keyways are protected by the same
patents and require a letter of authorization from the end
user. The difference between the C and D Families is
just the keyway. Despite the fact that Everest D Family
keyways are restricted keyways, they are still serviced in
the same manner as the C Family keyways. However,
D Family restricted keys can be cut reliably on key
bitting punch 40-099 because the top of the blade is not
straight.
The keyway for each restricted D Family job is selected
by Schlage and registered to the end user. Everest
restricted key blanks, cut keys, cylinders and plugs are
drop shipped directly to the end user (or a location spe-
cifically authorized by the end user). This creates positive
key control by preventing dealers and distributors from
having access to keys and cores without the end user’s
permission.
Primus®Integration
Primus®cylinders are also available with Everest
keyways. The Everest Primus keys are downward
compatible to operate the conventional Everest
cylinders covered in this manual. See the Schlage
High Security Cylinders & Key Control Service
Manual (SC-GN-1001) for details on Everest
Primus cylinders.
A portion of the undercut groove is milled away on all
conventional Everest keys to prevent them from being
altered to operate an Everest Primus cylinder.
Lip to lift
check pin
Lip removed to prevent
Primus operation

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Conventional Cylinders
Service Manual
Mechanical Overview
Shell
Tailpiece
Plug
Check Pin Spring
Check Pin
Retainer Cap
Top pins
Master Pins
(as needed)
Bottom Pins
Key
Tumbler
Springs
Retainer Cap Pin
Retainer Cap Pin Spring
Traditional Cylinder Modular Cylinder
Everest and Primus Classic Everest and Classic
Horizontal Vertical
Traditional Cams Modular Cams
Everest and Primus Classic For cylinder housing
sizes 1¹⁄₄, 1¹⁄₂, 1³⁄₄”
For cylinder housing
sizes 1¹⁄₈, 1³⁄₈, 1⁵⁄₈”
Mortise cylinders use the Primus cam with one screw. Modular cylinder cams may be used with Classic, Everest and Primus
key sections. Use appropriate cam for cylinder housing size.
Locked Unlocked
Cylinder Cross Section

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Service Manual
Modular Cylinders
Introduced in April 2010, the Schlage modular cylinder provides easy convertibility between key-in-lever to mortise
and rim cylinders. These benefits make Schlage cylinder inventory flexible, reduce the size and cost of inventory,
improve customer lead time, and increase customer satisfaction. With a few modular components in stock, the cylinder
type and finish required will always be on hand. The modular cylinder accepts a tailpiece or a mortise cam.
Product line availability: A, AL, B, CL, D, H, L, ND, S, S200, Kryptonite (PL, KS, KC), and Rim (standard and lockout).
All competitive locks that accept Everest Primus® will also accept the modular cylinders.
Key-In-Knob to Modular Mortise and Rim Cylinder Conversion
Modular Key-In-Knob Cylinder
Modular Rim Cylinder
Modular Mortise Cylinder
Modular Housing Interchangeability
Housing Cam Cam
Screw
Plug
Extension
Part
Number Size Part Number
B520-721 1¹⁄₈"L583-474 B520-690 —
B520-722 1¹⁄₄"L583-475 B520-690 —
B520-723 1³⁄₈"L583-474 B520-691 B590-298
B520-724 1¹⁄₂"L583-475 B520-691 B590-298
B520-725 1⁵⁄₈"L583-474 B520-692 B590-299
B520-726 1³⁄₄"L583-475 B520-692 B590-299
1³⁄₈"
1¹⁄₂"
1⁵⁄₈"
1³⁄₄"
1¹⁄₈"housing
1¹⁄₄"
Plug Extension
B520-299
Plug Extension
B520-298
Cam
L583-474 or
L583-475
Cam
L583-474 or L583-475
Cam
L583-474 or L583-475 Cam Screw, 1”
B520-692
Cam Screw, ³⁄₄”
B520-691
Cam Screw, ¹⁄₂”
B520-690

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Conventional Cylinders
Service Manual
The following instructions assume that the reader has
basic experience pinning conventional cylinders. The
difference with Everest™ cylinders is the check pin and
spring located in the special chamber on the bottom of
the plug. If using a key to remove the plug, the key will
hold both the check pin and check pin spring in place.
Rekeying When You Have the Old Key
(no master keying)
1. Remove the cam, tailpiece or other type of plug retainer.
2. Insert the old key and turn it slightly in either direction.
3. Push the plug out gently with a plug follower.
Key holds
check pin
in place
4. While the key is still in the plug to hold the check pin
in place, discard the old pins.
5. Hold the check pin in the plug with your finger or
thumb. Remove the old key and insert the new key.
6. The new key holds check pin in place while the bottom
pins are installed and the plug is put back into the shell.
7. Reinstall the cam, tailpiece, etc.
Lip raises check pin
and holds it in plug.
Master Keying
The master keying capacity of full size Everest™
cylinders is the same as Schlage Classic™ cylinders:
4,096 theoretical changes per keyway using two step
progression. The MACS is 7. When master keying
Everest cylinders, Schlage recommends using a setup
key to reinstall the loaded plug.
A setup key can be made by cutting a key blank to a 9
depth in all positions. When the steeples between the
cuts are removed, the setup key can hold the check pin
in place when removing the plug of a shimmed cylinder.
#9Depth Key for
Setup Key
1. Insert any operating key and turn it slightly in either
direction. Gently push the plug out with a plug follower.
2. Keeping the old key in the plug, discard the old pins.
Key holds
check pin
in place
3. Hold the check pin in position with a finger or thumb.
Remove the old key and insert the setup key. If you
are certain that the cylinder was not previously
master keyed, skip to step 5.
4. IMPORTANT: Clear the cylinder shell of any
remaining master pins. If master pins remain in the
shell, the following problems may occur:
• A key cannot be inserted or removed
• One or more springs may get crushed and cause a
future lockout
• Additional keys will operate the cylinder.
Slowly back the follower out of the shell. Replace any
weak or damaged springs. Load the proper size top
pin based on the plug total (bottom pin + any master
pins). A plug follower with a groove will help guide
each spring and top pin into its chamber as you push
the follower in from the back of the shell. (The 40-116
shell loading tool can make this process easier.)
5. Install new bottom and master pins into the plug.
6. Orient the plug so it is slightly turned with respect to
the shell. Gently push the plug into the shell, pushing
the plug follower out.
7. Test all keys for smooth operation.
8. Reinstall the cam, tailpiece, etc.

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Conventional Cylinders
Service Manual
Rekeying When You Have No Keys
When no key is available, use standard locksmith techniques to shim the cylinder open. However, the check pin must
be taken into account. Follow these steps:
1. Using a pick or key blank, shim the six pins as usual. After the last pin is neutralized, the plug still cannot rotate or
slide out because the check pin is engaged.
2. Leaving the shim in place, insert a setup key with no steeples between the 9
depth deep cuts. This unlocks the check pin and will also keep it from spring-
ing out of the plug in step 4.
3. Use the setup key to turn the plug slightly in either direction and remove the
shim.
4. Push the plug out gently with a plug follower.
5. While the setup key is still in the plug, discard the old pins. If you are certain that the cylinder was not previously
master keyed, skip to step 7.
6. IMPORTANT: Clear the cylinder shell of any remaining master pins. If master pins remain in the shell, the following
problems may occur:
• A key cannot be inserted or removed
• One or more springs will get crushed and cause a future lockout
• Additional keys will operate the cylinder.
Slowly back the follower out of the shell. Load the proper size top pin based on the plug total (bottom pin + any
master pins). A plug follower with a groove will help guide each spring and top pin into its chamber as you push the
follower in from the back of the shell. (The 40-116 shell loading tool can make this process easier.)
7. If you are master keying, leave the setup key in the plug. Otherwise, hold the check pin in position with your finger
or thumb while removing the setup key and inserting the new operating key.
8. Install the new pins in the plug.
9. Orient the plug so it is slightly turned with respect to the shell. Gently push the plug into the shell, pushing the
follower out.
10. Test all keys for smooth operation.
11. Reinstall the cam, tailpiece, etc.
For removing plug
when shimming

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Service Manual
Key Bitting Specifications
The following specifications are the same for Schlage Classic™ keys, including Primus®
MACS = 7
Increment: 0.15"
Progression: Two Step
Blade Width: .343"
Depth Tolerance: + .002" - 0
Spacing Tolerance: ± .001"
Root Depths
0 .335"
1 .320"
2 .305"
3 .290"
4 .275"
5 .260"
6 .245"
7 .230"
8 .215"
9 .200"
Pins and Springs
Bottom Pins Master Pins Top Pins
Size Length Part No. Size Length Part No. Size Length Part No. Application
0 .165" 34-300 2 .030" 34-202 1 .235" 34-101 Plug total = 0, 1, 2, 3
1 .180" 34-301 3 .045" 34-203 2 .200" 34-102 Plug total = 4, 5, 6
2 .195" 34-302 4 .060" 34-204 3 .165" 34-103 Plug total = 7, 8, 9
3 .210" 34-303 5 .075" 34-205
4 .225" 34-304 6 .090" 34-206
5 .240" 34-305 7 .105" 34-207
6 .255" 34-306 8 .120" 34-208 Other Pins and Springs
7 .270" 34-307 9 .135" 34-209 Description Part No.
8 .285" 34-308 Tumbler Spring C503-113
9 .300" 34-309 Check Pin 34-007
Check Pin Spring C603-951
Cap Pin C503-116
Cap Pin Spring C503-115
.031"
1.012"
100°
.8558"
.6996"
.5434"
.3872"
.231"
1234 56
Code Card
C45
for HPC 1200CM
Code Machine

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Conventional Cylinders
Service Manual
Cutting Everest™ Keys on the
Blue Punch
Handle
L-Handle
Die Carriage
Bottom Jaw
Cover Plate
Depth Number
Key Gauge
Depth Bar
Red Knob
Top Jaw
Bottom Jaw Key Stop
Clamp Into Groove
Between Ribs
The original version of this popular key machine was
developed in the mid-1970’s. Pro-Lok® is the most
recent in the succession of companies that have manu-
factured the machine. Even if you have what appears
to be an original Schlage punch (40-126), it was made
by one of the earlier companies. The basic principles
are the same for all versions of the machine, but there
are minor differences in the vise jaws which affect the
machine’s ability to cut Everest C Family keys.
Machines made before July 1999 were not designed to
hold Everest keys. Most of these machines have a thin
top vise jaw made of stamped steel. Some machines will
hold Everest keys, except sections with “45” in the des-
ignation (such as C145). Even the first generation solid
steel jaw was produced before Everest keys
existed and must be replaced.
You may be able to alter your old style jaw by slightly
elongating the hole, so it can travel far enough to
engage in C145’s groove. However, this solution should
only be a temporary measure until you install the 40-074
upgrade package with the properly shaped top jaw.
Elongate
In the close-up illustrations of the vise, notice the
different positions of the top jaw required to engage the
grooves and seat the different shapes of Schlage key
sections properly.
Left end of vise
Obverse Key Sections C, CE, E, EF, F, FG, G, H, J, K, L
Loosen knob
and lift jaw.
Most Everest Key Sections:
C100, C120, C123, C124, C135, C150
Loosen knob
and lift jaw
toward top
of key blade.
Everest "45" Sections: C145, C245, C345
Not only must the top jaw engage in different places
up and down the side of the various key sections, but
the lever or knob screw must be tightened or loosened
substantially. Loosening and tightening the lever or knob
screw allows enough travel in the top jaw to accom-
modate the difference in thickness between Classic™
and Everest key sections, and to adjust for the angles at
which the top jaw sits.

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Conventional Cylinders
Service Manual
Upgrading to New Top Jaw
Red Knob Operation
Tighten the red knob on the Obverse key sections or
loosen it enough to let the top jaw move up to grab into
the high groove of C145, or anything in between.
Black Lever Operation
Pro-Lok changed the red knob to a black clutching lever
in 1998, before Everest™ keys existed.
The lever can only swing about 180° before hitting the
body of the machine. If the Blue Punch is used only to
cut one type of Schlage key section, the lever’s travel
may be set for fast secure clamping every time.
The black lever does not allow the top jaw to travel from
its lowest position (for Obverse keys), to an intermediate
position (for clamping most of the Everest C Family keys),
to the highest position required (for C145). Commercial
locksmiths who cut a variety of Schlage key sections daily
may find the continuous lever adjustment inconvenient.
On most machines, the lever must be specifically adjusted
for each of the three clamping positions.
Use the following procedure to back the screw out for
Everest keys or to tighten the screw for Obverse keys:
1. Lift the lever against spring pressure to disengage it
from the screw.
2. While disengaged, swing the lever to the left or right
without turning the screw.
3. Let go of the lever and it snaps back into
engagement with the screw.
Upgrade Package 40-074
A newly designed top jaw, red knob, spring, finishing
washer and regular washer can be obtained from your
Schlage or Pro-Lok distributor.
Changing the top vise jaw has no effect on the accuracy
of the machine. If the machine exhibits mechanical
problems or cannot cut keys accurately, please contact
your Pro-Lok distributor to arrange for your machine to
be rebuilt.
Red Knob
Finishing Washer
Spring
Washer
Top Jaw
40-074
Upgrading Machines With a Red Knob
1. Unscrew the old knob.
2. Remove the old top jaw.
3. Install the new pieces. Install the jaw so the end with
the longer angled portion is toward you. The end with
the shorter angle has a lip to engage in the groove of
the key section.
4. Screw on the new red knob.
Long Angle
Upgrading Machines With a Black Lever
1. Swing the lever as far to the right as it will go. Lift up
against spring pressure to disengage it from its screw.
2. Swing the lever back as far to the left as it will go and
let it down to engage the screw.
3. Repeat this process as many times as necessary to
unscrew the screw completely and remove the lever.
A hex wrench may be helpful.
4. Remove the lever, spring, washer and top jaw.
5. Install the new jaw so that the end with the longer
angled portion is toward you. The end with the
shorter angle engages the groove in the key milling.
6. Reinstall the black lever or install the new red knob
depending on your preference: The red knob screws
into place. If reinstalling the black lever, use an Allen
wrench to start the screw, then reverse the process
used to remove the lever. To adjust the lever's final
position and rotation, clamp a single key or key blank
of the key section you will cut most frequently.
Hex Socket
Lift Up Against Spring Pressure
While Backing Screw Out

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Conventional Cylinders
Service Manual
Tips for Cutting Everest™ Keys
After cutting several keys of each key section the procedure will become familiar. However, for the first few keys,
please observe these important details:
• Push the die carriage all the way to the right before inserting a key blank. If you clamp an Everest key before
moving the carriage, its large bow may prevent the carriage from travelling far enough to allow the first cut to be
correctly positioned. (Cut position will begin at #2 and incorrectly cut the key.)
• Closely observe the proper engagement of the top jaw into the key section. If the jaw clamps on the surface of
a rib or into the very bottom relief on an Everest key, the key jaw is not able to square up the blank in the vise,
incorrectly cutting the key.
C124 C145
C124 and C135 have tiny grooves. Be sure jaw
engages into a groove.
The position of the groove on C145, C245 and C345
blanks requires loosening the knob and pushing the jaw
toward the cutter to securely engage the groove.

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Key Blanks
Operating Keys
DO NOT DUPLICATE
PAT. 5,715,717 PAT. 5,715,717
DO NOT DUPLICATE
PAT. 5,715,717
Front
Back
35-002
Standard for D Family
Optional for C Family
35-009
Standard Front
for C Family
35-002 and 35-009
Back
35-015
Optional Plain Bow
for C and D Families
Control Keys Cut Keys
DO NOT DUPLICATE
PAT. 5,715,717
CONTROL
PAT. 5,715,717 To order cut keys:
Change "35" prefix to "48" or "49"
48 = Change keys and random or stock
cut keys
49 = Factory master level key, including
control keys
35-003 (Front) 35-003 (Back)
C Family Open Keyways
C145
C150
C135
All-Section Key
Multi-Section Keys
Multi-Section Keys Multi-Section Keys
C120
C124
C000
C123
C200
C245C234
C230
C235 C345C134
C100
C125
Keyways and Single Section Keys
New keyway systems begin
here and continue to the right.

© 2010 Ingersoll Rand SC-5424 Rev. 8.10 Printed in U.S.A.
877.671.7011 www.schlage.com www.ingersollrand.com