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Kaba 5402 Series, Technical Manual

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Kaba 5402 Series Technical Manual Download Page 39

Technical Manual

Section 3: Key Cutting and Pinning

Summary of Contents for 5402 Series

Page 1: ...Technical Manual...

Page 2: ...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 Lub...

Page 3: ...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...

Page 4: ...in 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...

Page 5: ...Technical Manual Section 1 Introduction...

Page 6: ...ontrol 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 technolo gy made pop...

Page 7: ...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...

Page 8: ...ylinder 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 an...

Page 9: ...tributor locksmith keyways none not patented Commonly called restricted keyways none not patented The primary purpose of patented high security locks is the prevention of unauthorized key duplication...

Page 10: ...oth 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 cyli...

Page 11: ...Technical Manual Section 2 Product Information...

Page 12: ...ars 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 befo...

Page 13: ...ide for Sargent exit devices plug shell assembly break off screws 2 required backplate 3500 xx 2003 collar finish to match cylinder Each 5402 cylinder assembly includes these components 4701 98 4118 s...

Page 14: ...es Hana knobs 33 Falcon X series knobs except Hana 12 Falcon B series grade 2 levers 18 Falcon F series levers 17 Falcon N series knobs 17 Falcon LY grade 1 levers 23 Falcon RU grade 1 unit locks 01 F...

Page 15: ...st motion tailpiece 3450 00 2000 single cylinder lost motion tailpiece 3450 80 2004 timing washer 3450 80 2003 spacing washer 1590 80 2000 SD 3A 4700 80 2001 SA 3B 4700 80 2002 S 3C The 95 cylinder ki...

Page 16: ...4001 staking tool 6840 00 3540 staking fixture 3800 00 3548 ejector tool Universal A2 3400 00 5012 Universal A4 3400 00 5004 Schlage RC 6440 00 5002 5400 00 5025 Global Parts Kit With discs fillers a...

Page 17: ...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 ARROW Single cylinder deadlocks 5400 xx 1099 uncombinated and...

Page 18: ...first filing it narrower top to bottom CAL ROYAL BA grade 2 knobs 5400 xx 1099 uncombinated and use 4700 80 2001 SA 3B tailpiece horizontal 3450 80 2003 spacing washer 99 plug shell large diameter pl...

Page 19: ...ity bushing S 3C 99 plug shell large diameter plug requires J or K series bottom pins CORBIN CL3800 grade 2 levers RUSSWIN 5400 xx 1099 uncombinated and use the original Corbin Russwin tailpiece and p...

Page 20: ...e Falcon no 030730 005 30 Falcon parts are 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 99 p...

Page 21: ...etainer TPR 1 Falcon parts are not supplied 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...

Page 22: ...ng cylinder uncombinated P tailpiece must be requested 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 vertic...

Page 23: ...deadlocks 5400 xx 1099 uncombinated and use 3450 00 2000 lost motion tailpiece 3450 80 2004 timing washer or use LSDA tailpiece and driver 99 plug shell large diameter plug requires J or K series bot...

Page 24: ...pass 5400 xx 1099 uncombinated and use 1590 80 2000 SD 3A tailpiece horizontal 3450 80 2003 spacing washer MASTER Padlocks see page 2 21 99 plug shell large diameter plug requires J or K series bottom...

Page 25: ...om pins 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 wash...

Page 26: ...ould protrude from this side 99 plug shell large diameter plug requires J or K series bottom pins SARGENT 5500 Line imported grade 2 knobs 5400 xx 1099 uncombinated and use 4700 80 2001 SA 3B tailpiec...

Page 27: ...0 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 SCHLAGE A...

Page 28: ...200 and H locksets 5400 xx 1099 uncombinated and use 3450 00 2000 lost motion tailpiece 3450 80 2004 timing washer SCHLAGE C D Series grade 1 knobs 5400 xx 1099 uncombinated and use 1590 80 2000 SD 3A...

Page 29: ...ts 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 interchan...

Page 30: ...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 Weiser tailpiece and retainer Weis...

Page 31: ...nated 3425 82 3012 tailpiece 3425 00 4012 retainer pin 1 16 roll pin Same as 5400 xx 1054 cylinder above but with tailpiece YALE 5300LN grade 2 levers 5400 xx 1095 uncombinated 3450 80 2003 spacing wa...

Page 32: ...eries Use adapter 0298 0626 from Master American 3600 3700 Use with modified adapter See below 1 L adapter 2 shorten adapter 3 notch for key tip and retainer ring Dealers have reported that shortening...

Page 33: ...0 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...

Page 34: ...40 staking fixture and 6440 00 4001 staking tool required face of plug is key stop for longer core life no restricted control combinations This product uses a large diameter plug J series bottom pins...

Page 35: ...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 63...

Page 36: ...06 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 Use 6340 00 4012 timing pin 6800 00 20...

Page 37: ...ks remain visi ble 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 t...

Page 38: ...Section 2 27 Product Information Peaks Global Notes...

Page 39: ...Technical Manual Section 3 Key Cutting and Pinning...

Page 40: ...g 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...

Page 41: ...cking pin Global Assembly Insert the plug into the housing or cylinder for final assembly Inserting Discs and Fillers Insert discs part number 5400 00 4002 into the Global plug disc slots that corresp...

Page 42: ...scs 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 The...

Page 43: ...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 Inserting Peaks Patented Bottom...

Page 44: ...rt 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 Position top pin into plug follower slot With pin depressed...

Page 45: ...om 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 an...

Page 46: ...ped Cores should be stamped on the top half of the shell Mortise and rim cylinders should be stamped on the back of the shell Lubrication Kaba recommends the use of Superlube for all Peaks Global cyli...

Page 47: ...and 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 h...

Page 48: ...ified 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...

Page 49: ...ty 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 w...

Page 50: ...nd void the product warranty S indicates spool type pins Bottom pins are nickel silver Top pins are brass system top pin part number length A2 A4 3800 00 4202 025 2B 4203 0375 3B 4204 050 4B 4205 0625...

Page 51: ...taking 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 no...

Page 52: ...ome 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...

Page 53: ...t use excessive force 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 t...

Page 54: ...26 Use 5240 xx 1006 to retrofit Yale 1210 and 5240 xx 1007 for Yale 1220 5240 cores use the following components A2 system A series bottom pins and B series top pins A4 system E series bottom pins and...

Page 55: ...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 mak...

Page 56: ...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...

Page 57: ...3800 00 4010 Stack height 26 control CTR 779631 master AA 951473 change 1AA 593875 Key in Knob top 17 17 12 18 19 11 buildup 11 10 master 4 4 2 4 2 bottom 5 5 1 4 7 3 7B 5400 XX 1206 Rim Mortise 5401...

Page 58: ...ng 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...

Page 59: ...es the bottom pin A master pin makes up the differ ence 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 b...

Page 60: ...0 top 6 7 10 7 10 6 buildup 6 7 7 6 master 1 1 1 5 bottom 2 0 4 1 0 3 top 6 7 10 7 10 6 buildup 6 7 7 6 master 1 1 1 5 bottom 2 0 4 1 0 3 top 8 4 6 9 5 7 control 4 10 4 5 5 5 master 1 1 1 5 bottom 2 0...

Page 61: ...l 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 t...

Page 62: ...Section 3 23 Key Cutting Pinning Peaks Global Notes...

Page 63: ...Technical Manual Section 4 Key Control Record Keeping...

Page 64: ...umber 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 keepi...

Page 65: ...one 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 2 No Current Signatories a Declaration of Authority Let...

Page 66: ...aks Global key system P001 I au thorize you to furnish the keys and cylin der on the attached order Sincerely John Doe enc purchase order 621 AA Locksmith 1 Main Street Winston Salem NC 27105 The Init...

Page 67: ...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 change...

Page 68: ...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 C...

Page 69: ...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 exam...

Page 70: ...ri ty 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...

Page 71: ...ull 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 k...

Page 72: ...an 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 i...

Page 73: ...Technical Manual Section 5 Cylinder Installation Guide...

Page 74: ...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 To...

Page 75: ...tamped 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 orientation vary Yale...

Page 76: ...ade 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...

Page 77: ...2 knobs import KDH Non KDH in development 300 500 UT5200 grade 1 unit locks Non KDH 5400 xx 1004 or 5140 large format interchangeable core TOOLS Grade 1 levers CL3400 and CL3600 require 585F48 hex wre...

Page 78: ...r wrench depress knob retainer 2 Remove inside trim remove lock from door Older locks do not have this plate 3 Depress outside knob retainer remove outside knob 4 Remove knob cap if present 5 Remove r...

Page 79: ...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 rem...

Page 80: ...eadbolts accept only 6 pin small format interchangeable core knob Falcon Lock Co Marks USA Falcon LY series X series RU and X series S series D series grade 1 grade 1 grade 1 unit lock grade 2 tubular...

Page 81: ...ent bushing wrench 10 0022 Section 5 8 Cylinder Installation Guide Sargent 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...

Page 82: ...Unscrew spindle from knob Slowly separate knob and spindle Observe order of parts and save them including the roll pin aligner tube knob retainer spring visible through hole in aligner tube 2 Lock mus...

Page 83: ...th new locks is required to install AL grade 2 leversets but not to change the cylinders 1 16 pin punch for depressing retainer NOTES Original S series tailpiece must be used in 5400 xx 1099 cylinder...

Page 84: ...Section 5 11 Cylinder Installation Guide Peaks Global Notes...

Page 85: ...Section 5 12 Cylinder Installation Guide Peaks Global Notes...

Page 86: ...KAA1134 0209 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...

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