Cal-Royal High Security Cylinder Service Manual

Mortise / Rim / Key in Knob / Lever Cylinders
Large Format and Small Format Interchangeable Core Cylinders
6605 Flotilla Street, Commerce, California 90040 U.S.A. 1-323-888-6601 1-323-888-6699 { [email protected] www.crpsecurities.com
EDED C ONTENTS EDED
System Controls and Levels of Security
1
Product Information
2
x
x
x
Key Blanks
Pin and Key Cutting Information
Side Bars, Side Pin, Stainless Bottom Pin Specifications
Standard Cylinder Information
x
x
x
x
Large Format Cylinder Information
x
x
x
x
10
Design Information
Components
Cylinders Servicing
Cylinder Keying and Pinning
Tools and Service Kits
x
x
x
x
x
7
Design Information
Components
Cylinders Servicing
Cylinder Keying and Pinning
Small Format Cylinder Information
x
x
x
x
4
Technical Design Information
Components
Cylinders Servicing
Cylinder Keying and Pinning
17
Pinning Kits
Cam Kits
Service Kits
UL Pin Kit
Small Format Parts
Master Keying Cylinders and Keying Systems Applications
Appendix
x
x
x
x
x
APPENDIX A – Key cutting key technical information for LFIC
APPENDIX A-1 - HSK cut form / Maximum cut range
APPENDIX B - Key cutting key technical information for SFIC
APPENDIX C – (HSK MC/RC Shell) - Tail Piece Shears
Sample Dealer Agreement
x
Tool Resources
21
System Controls and Levels of Security
High Security Cylinder Program Levels
Level 1
The “A” Standard keying and “1A” Small Format Interchangeable Core are open locksmith
Keyway *** See Authorization Card Below
Level 2
The Locksmith Service Center program assigns specific Keyways by geographical areas with
care to not overlap keyways between Service Areas. Key Duplication is controlled at the Service
Center by Authorized personnel and Registered Card Program. *** See Authorization Card
Below
Level 3
A. The Contract Hardware House Program sells Cylinders and locks under 2 programs
1.) In conjunction with authorized Locksmith Center. Here the Contract Hardware
supplier will have a working agreement with a Locksmith Service Center to maintain
a specific job and cut keys for the Authorized Point of Contact.
2.) Government Contract Job or Factory Only Systems. On government Contract jobs
the keyway will be set by the factory and blanks will be maintained by the end user
and only released for cutting or rekey purposes by the Authorized individual to their
locksmith or Locksmith Service Center.
3.) Factory ONLY jobs will require that all keys be cut and supplied directly the end user
by authorized end user agreement.
B. Distributor Program
This program is for the Distributor who sells to large institutions who employ their
own locksmiths and who need the added level of security of a special key way
restriction. The Distributor may sell blanks to their end user for specific jobs or
may control the duplication at their facility based on contractual agreement.
Level 4
Factory ONLY jobs will require that all keys be cut and supplied directly the end user by
authorized end user agreement. Any normal Cal-Royal Authorized individual may sell this type
of job. However ONLY the Factory will be authorized to supply CUT KEYS and the keys will be
sent directly the end user ONLY sent directly to the Authorized agent at the End User Facility.
Authorization Card – Each Cylinder Combination comes with an Authorization Card.
For
Master Key Systems Job Specific Cards will be Issued from the Factory for the Job. For End
User Projects the Authorization Cards will be Issued from the Factory and will be required to be
validated prior to cutting and transmission of Keys.
F 1 G
Product Information
Product Information
Key Blank Information
Standard Full Size Key Blanks
KBL-5 -( Keyway)
KBL-6 -( Keyway)
When Ordering Full Size Key Blanks add Keyway Designator i.e. KBL-6 –A
Large Format Interchangeable Core Control Keys
KCK6-(Keyway)
When Ordering Large Format Interchangeable Control Keys order KBLK-6-A
Key Cutting Technical Key Data
See APPENDIX A, A-1, B
Pin information
Full Size Cylinders use Schlage standard Pins and Pinning information.
Bottom Pins
Master Pins
Side Pins
0-.165
1-.180
2-.195
3-.210
4-.225
5-.240
6-.255
7-.270
8-.285
9-.300
2-.030
3-.045
4-.060
5-.075
6-.090
7-.105
8-.120
9-.135
SPIN1
SIDEBARSPRING
SPIN2
SPIN3
SIDEBAR-1
SPIN4
F 2 G
Product Information
Side Bars, Side Pins, Stainless Bottom Pin Specifications
Standard Cylinders
Side Bar for Large Format Cylinders
Product Number is Side Bar-1.
The Side Bar is actuated through the movement of the Side Pins along the side pin track on the
key blank. When the side pins align with the proper track the side bar will be allowed to retract
into the cylinder plug and the cylinder will operate provided the key is cut to the proper
combination for the cylinder.
The Side Bar is the same for all Large Format Cylinders. Side Bar springs push the side bar into
the cylinder shell when the plug is not rotated.
Side Pins
There are five side pins in the large formant cylinder. There are four configurations of side pin
for the Large Format cylinder numbered SPIN1 through SPIN4. Each Side pin has a Side Bar
Groove cut at a specific position on the pin to allow the side bar to retract into the cylinder plug
when properly aligned in the side bar track on the key blank.
Anti drill features
Each cylinder contains 2 anti-drill pins for those with concerns about a drill out attack.
UL 437 Cylinders contain 9 anti-drill pins.
Anti-Pick Features
The cylinder side bar substantially reduces the ability to pick the High Security Cylinder,
combined with the cylinder pins aligning 11 separate pins at two different shear points provides
what we believe to be one of the finest pick and bump resistant cylinders o n the market. (5 side
pins must align to the side bar at the same time that the 5 or 6 cylinder pins align at the plug
shear line.)
Stainless Steel Pins for UL Cylinders
The Stainless Pins for our UL High Security Cylinder consist of 10 Bottom Pins numbered 0
through 9 and our Mushroom Top Pin and our Stainless Allen Set screw for securing each pin
chamber.
The Pins are numbered as Follows:
UL Bottom Pins
0 - SSBPIN0
1 - SSBPIN1
2 - SSBPIN2
3 - SSBPIN3
4 - SSBPIN4
5 - SSBPIN5
6 - SSBPIN6
7 - SSBPIN7
8 - SSBPIN8
9 - SSBPIN9
UL Special Pins
ULMSHRMTPIN
(UL-Mushroom top pin)
ALLNSCRW-SS
(SS Allen screw)
F 3 G
Standard Cylinder Information
Standard Cylinder Information
Technical Design Information
High Security Cylinders are available in 6 pin Mortise / Rim, Key in Knob / Lever, Deadbolt and
Large Format Interchangeable Cores. High Security Cylinders are also available in 5 pin Key in
Knob / Lever, Deadbolt cylinders.
High Security Cylinders incorporate a Side Bar, Side Pins, and Side Bar springs. The side bar
pins ride along the side bar track on the key blank. In each Standard Cylinder there are five side
pins of varying lengths. There are four different side bar pin configurations. This allows for 1024
different side bar combinations available for each Keyway in the Standard Size Cylinder
Program. Side bar combinations are assigned at Cal-Royal Products. When the side pins align
with the correct side track the pins also align with the side bar and allow the plug to rotate freely.
The slight click felt when rotating the plug is the side bar moving into the plug from the cylinder
housing, this is normal.
Keying and Master Keying of Standard cylinders is done using conventional Schlage style pins
and pinning. Pin Spacing, Depths and Cutting is identical to Schlage Cylinders.
***See chart in APPENDIX A-1
Components
Each Key in Knob / Lever cylinder comes with all of our tailpieces provided.
Mortise
Cylinders
ortise / Rim C
linders are provided
pro ided with
ith a Rim Tailpiece, mounting screws and mounting plate
for Rim Function they come assembled with an Adams Rite mortise cam.
F 4 G
Standard Cylinder Information
Design requirements necessitate the use of special Cams with Mortise Cylinders. Cams
available from Cal-Royal Products are shown below are available by cam or in our cam kits
sets. *** See Tools and Service Kit Section
UL High Security Cylinders are 6 Pin ONLY and require the use of ten anti drill pins and the
SSPIN allows us to comply with UL requirements. UL Cylinders include Mortise / Rim, Key in
Knob / Lever and Deadbolt Cylinders and Large Format Interchangeable Cores.
Standard Cylinder Servicing
There are two methods of Keying the High Security Cylinder one is to remove the plug and key
using conventional methods.
When removing Plug from Cylinder housing Hold Side Bar in the Plug. Keep pressure on the
side bar at all times unless removing the side pins.
Insert plug into pinning block to prevent side bar from releasing the side pins from the plug.
F 5 G
Standard Cylinder Information
Pin Cylinder and replace in to Cylinder Housing.
Check key / keys for correct function and replace Tail Piece or cam as required.
When replacing the side pins for Side Bar profile change:
1. Remove plug from housing.
2. Remove the key from the plug while holding the side bar loosely.
3. Remove side bar and side bar springs side pins will drop out of the plug at this point
4. Insert new side bar pins
5. Replace side bar springs and side bar.
6. Place plug in pinning block and pin as required.
a. Make sure that the top pin is correct length for stack of bottom pin and master
pin. Stack equals Bottom Pin plus Master Pin added together.
b. The proper stack by top pin follows:
0-3 Bottom Stack # 1 Top Pin
4-6 Bottom Stack # 2 Top Pin
7-9 Bottom Stack # 3 Top Pin
7. Re-install plug in cylinder housing and check keys for correct function.
8. Install tailpiece or cam as required.
9. Lubricate with dry black graphite. (Small Amount)
The Second method is to simply remove the Allen set screw capping each pin chamber. This
method removes the need to deal with the side bar and side bar pins. The process is much
simpler as follows:
1. Remove each set screw.
2. Remove existing springs and pins.
3. Install new pins and springs.
a. Make sure that the top pin is correct length for stack of bottom pin and master
pin. Stack equals Bottom Pin plus Master Pin added together.
b. The proper stack by top pin follows:
0-3 Bottom Stack # 1 Top Pin
4-6 Bottom Stack # 2 Top Pin
7-9 Bottom Stack # 3 Top Pin
4. Check function.
5. Replace set screws.
6. Check function and Lubricate with dry black graphite. (Small Amount)
It is recommended that when rekeying cylinders all bottom pins be replaced each time as wear
factor is relational to the position of the pin in the cylinder. The first pin wears at six times the
rate of the last pin in the cylinder. On cylinders with 1000 key insertions and removals the first
pin has 12,000 times the wear of the last pin. Conversely the key wears six to one tip to bow.
F 6 G
Large Format Cylinder Information
Large Format Interchangeable Core Cylinder Servicing
When Pinning the Cylinder:
1. Remove Cylinder Cap by depressing the retainer pin and unscrewing the cap.
2. Insert key and remove plug. When removing Plug from Cylinder housing Hold Side Bar
in the Plug. Keep pressure on the side bar at all times unless removing the side pins.
Insert plug into pinning block to prevent side bar from releasing the side pins from the
plug. Pin Cylinder and replace in to Cylinder Housing. If cylinder had been previously
pinned make sure the master pin left in the core housing are removed.
3. Remove existing Pins from plug.
4. Remove existing Top Pins and Springs.
5. Pin Plug using appropriate Bottom and Master Pins.
6. Install Top Springs and proper length Top Pins
a. Make sure that the top pin is correct length for stack of bottom pin and master
pin. Stack equals Bottom Pin plus Master Pin added together.
b. The proper stack by top pin follows:
0-3 Bottom Stack # 1 Top Pin
4-6 Bottom Stack # 2 Top Pin
7-9 Bottom Stack # 3 Top Pin
7. Reinstall plug into Cylinder housing.
(Use caution to hold side bar in place or side pins will drop out of plug)
8. Check function and that all keys work properly.
9. Re-install Cylinder Cap and check for smooth Operation.
F 7 G
Large Format Cylinder Information
Keying and Master Keying Full Size Cylinders
HSK Full Size cylinders pin using the same Key cuts and Pins as Standard Schlage Cylinders.
Keying and master Key Systems for practical applications are the same. To facilitate Master
Keying systems we will provide some basic rules and reasons for selection of Master and Grand
Master Key systems.
For selection of a Master Key (TOP) in any given system take into consideration the following
rules.
RULE
REASON
1. The Top Key of a Master Key System is used
1. Place no cut deeper than ½ the cut range in the
extensively, with a deep cut in the first chamber
first chamber.
keys will break often.
2. Make one cut of the Master Key a zero or a one 2. This prevents a change from being altered into a
cut.
Master key.
3. Make one cut an eight or a nine cut.
3. By having one cut deeper than any other, you
prevent someone from making an impression of a
Master Key under normal conditions.
4. By having constants between Progression
4. Where possible place constants between
numbers, this will allow the most useable keys for
progression numbers.
the system.
5. Reasonable expansion is the hardest item to
judge, a good rule of thumb is four to five times
5. Allow room for reasonable expansion, but keep
the original job scope. Always keep in mind, you
in mind the more pins in the lock cylinder the
know your customer best and their growth
more keys that will work the lock.
patterns. Sometimes this is way too much and
sometimes way too little.
F 8 G
Large Format Cylinder Information
In setting up systems for Cal-Royal to key, we recommend the following format and use of
standard key system nomenclature as specified below.
For a straight Master Key System use the following:
MK AA
1AA
2AA
3AA, Etc…
For a Grand MK System use the following:
AMK
AAMK
ABMK
ACMK
ADMK
AA-1 thru
AA64
AB-1 thru
AB 64
ACMK thru
AC 64
AD 1 thru
AD 64
For a Great Grand MK System use the following:
GMK
AMK
BMK
CMK
DMK
AAMK
AA1 – AA64
BAMK
BA1 –BAA64
CAMK
CA1 –CA64
DAMK
DA1 –DA64
ABMK
AB1 – AB64
BBMK
BB1 –BB64
CBMK
CB1 –CB64
DBMK
DB1 –DB64
ACMK
AC1-AC64
BCMK
BC1 –BC64
CCMK
CC1 –CC64
DCMK
DC1 –DC64
ADMK
AD1 – AD64
BDMK
BD1 –BD64
CDMK
CD1 –CD64
DDMK
DD1 –DD64
See Attached Forms under Master Keying Cylinders and Keying Systems Applications
section for Assistance in setting up key systems.
*** Notes
Special Note when keying cylinder plug for High – Low Master key you should cut a set-up key
cut all “9”’s. This will allow you to re-insert the plug back into the housing in the turned position.
Pin the cylinder as normal insert the set-up key and insert the plug. (Without the set-up key the
side bar will not retract, in order to install plug it would be necessary to place shim over pin
chambers and install, then remove shim.
F 9 G
Small Format Cylinder Information
Small Format Interchangeable Cores
Key Blank Information - Small Format Key Blank
When Ordering Small Format Key
Blanks add I prior to Keyway
Designator i.e. KBLSF7–IA
Key Cutting Technical Key Data
***See APPENDIX B
Small Format Interchangeable Cores offer a unique mix of speed for cylinder change out and
with the added features of pick and bump resistance. The patented keyway and side bar in our
Small Format Interchangeable Core provide the customer with a secure key control system at a
reasonable per unit cost.
Keys are controlled under the High Security Cylinder Service contract program. As with full size
high security cylinders our small format Interchangeable cores are sold under contract through
authorized
dealers.
The features of the small format Interchangeable core are much the same as full size cylinders.
The side bar works in conjunction with side pins to provide anti-bump and pick features. There
are four side pins each location having 3 side pin configurations giving us 81 possible side bar
settings.
*** Note Cal-Royal only has seven pin SFIC.
The six pin core has side pins between 2,3,4,5 pins while the seven pin core has the side pins
between the 3,4,5,6 pin locations of the plug. This has special factory authorized Master Key
system uses that allow both six & seven pin system to overlap in specifically designed projects.
Cross over Key Control in the six versus seven pin Interchangeable core is achieved due to
side pin locations:
The six pin core uses locations
2345
The seven pin core uses locations
3456
The six pin master key side bar pin cuts could be
The seven pin master key would be
The Grand master key working both six and seven pin cores would be
F 10 G
1112
1123
11123
Small Format Cylinder Information
This is a Factory authorized keying system ONLY. This application might be used where both
six and seven cores exist in a multiple site project and one grand master is needed. Extreme
caution is needed where this application is used not to cross over in the master key system.
Side Bar for Small Format Interchangeable Core
Product Number is SFICSIDEBAR
The Side Bar is actuated through the movement of the Side Pins along the side pin track on the
key blank. When the side pins align with the proper track the side bar will be allowed to retract
into the cylinder plug and the cylinder will operate provided the key is cut to the proper
combination for the cylinder.
The Side Bar for Small Format Interchangeable cores is different from the Large Format
Cylinders, however there is only on side bar for all Small Format Cylinders.
Side Pins
There are four side pins in the Small Formant cylinder. There are three lengths of side pin for
the Small Format cylinder numbered SFICPIN1 through SFICPIN3. Each Side pin has a Side
Bar Groove cut at a specific position on the pin to allow the side bar to retract into the cylinder
plug when properly aligned in the side bar track on the key blank.
Small Format Interchangeable Core
Small Format Interchangeable Core Cylinders use Best/Falcon Pins and Key Cutting
Information.
Pin Requirements for Keying
Bottom Pins
0- .110
1- .1225
2- .135
3- .1475
4- .160
5- .1725
6- .185
7- .1975
8- .210
9- .2225
Master Pins
2- .025
3- .0375
4- .050
5- .0625
6- .075
7- .0875
8- .100
9- .1125
10- .125
11- .1375
12-.150
13-.1675
14- .175
15- .1875
16- .200
17- .2125
18- .225
19- .2375
Side Pins
SFICPIN1
SFICSBSPR
SFICPIN2
FICPI
SFICSIDEBAR
SFICPIN3
SFICALLNSCRW
F 11 G
Small Format Cylinder Information
Servicing the Core
The core itself only needs to be disassembled
sassembled
when changing the side pins. Below an
exploded view of the core shows a part break
down.
To disassemble the core:
1. Remove the Allen set screws and remove all
pins.
2. Remove Plug Snap Ring (be careful
reful not to
distort clip).
3. Remove Plug, as plug is removed
ed the key
must be inserted in the plug to hold
old the side
pins in place or pins will fall out of plug.
4. Place Plug in Holding block key in place to
keep side bar and side pins in place.
ce.
5. To replace side pins Remove side
e bar and key
ke and side pins should
sho ld fall out
o t of the core.
core
a. Install new side pins, install side bar springs and side bar.
b. When installing side pins position the core with the side bar slot facing up.
c. insert the first side pin and check for correct alignment by inserting key.
d. repeat this procedure for each side pin.
e. install side bar springs and side bar. **** Note installing the side Bar incorrectly will
result in lock up of the core it will be scrap. The Side bar must be installed with the
longest side facing away from the plug. This side is tapered to fit into the side bar
groove in the core body.
6. Replace plug into core and install snap ring.
7. Pinning the core is identical to keying Best / Falcon style Small Format Interchangeable
cores.
8. Capping the individual pin chambers is different in that we use Allen set screws to secure
each pin chamber. This removes the necessity to have a capping block or capping press to
service the core.
Small Format Core installation information
Our Mortise / Rim cylinder has one of the drive pins shorter than the other. This is due to the
location of the side bar which requires additional space in the core. When using existing
cylinders by others or changing from an existing system to the High Security cores you will have
to cut down the left side drive pin in the cylinder housing. (Left side as you face the front of the
cylinder) This can be accomplished by using our tool and a drill motor. We also have a Shear
Tool for this same process. *** See “Tools Needed” under Tools and Service Kits section or see
APPENDIX C
For installation of cores in Key–in–Knob / Lever sets we have the Tailpiece for 6 and 7 pin cores
with the short drive pin on the left side.
F 12 G
Small Format Cylinder Information
Cutting Keys for the HSK Small Format Interchangeable core
The high security Small Format Interchangeable Core uses the same pins and cuts as any Best
/ Falcon Interchangeable Core. However the keys cannot be punched due to the keyway
Configuration. Cutting can be accomplished using one of several machines, a Partial list follows
1. ITL 900
4. Framon Code Machine 2J
2. Ilco Universal II
5. HPC Code Max 1200
3. Ilco EZ code
Etc.
Pinning Requirements for Keying Small Format
Interchangeable Cores
This section is for the individual who has never keyed a small format interchangeable core.
Keying Interchangeable cores in not as difficult as many make it out to be. There are however
several considerations in the keying process:
1. Keys are cut tip to bow. This means the core pins back pin chamber to the front pin
chamber. (The reason for this is simple and makes sense when understood, the shoulder of
the key blank is at the tip at the bottom of the key)
2. The pin Stack in each chamber is a total of 23 increments.
a. This prevents the springs from being crushed.
b. Having a stack of less than 23 gives insufficient spring pressure to properly return all
pins to their seated position.
3. The interchangeable works with two shear lines.
a. The control Key works at the Control shear line
b. Change and Master Keys work at the Plug shear line.
4. The Control Sleeve is ten increments thick.
a. This is a key factor in calculating the pins for each chamber.
b. Keep in mind that there are two shear lines in an interchangeable core.
5. Keying and Master Keying at the plug shear line is the same as any other cylinder.
6. Selection of a Control Key has two important factors when keying or master keying.
a. Where there is a 9 cut in the control key no 0 cut can be in any change key or master
key.
b. When selecting a control key the process should be where there is an even cut in
master key use an odd cut in control.
c. Where there is an odd cut use and even.
d. Repeat this process in all but one chamber keep that the same.
Example:
Master Key Cuts
Control Key Cuts
5 9 8 1 0 1
4 3 5 8 3 4
DS D DDD
D= Different S= Same
This prevents a change key from acting as a control key in large keying systems.
Writing a pinning chart and making the calculations for the control shear line to work the control
key.
There are two methods of calculating pins for the pinning of a small format
F 13 G
Small Format Cylinder Information
Interchangeable core and three numbers that control the math. The control sleeve is 10
increments thick, the total stack of the pins in each chamber is 23 and the difference is 13. With
this in mind we can start to do the math:
1. Step one enter the bottom pins in the chart.
2. Step two add ten (10) to the cut of the control key and subtract the cut of the bottom pin
from this number to get the length of the control pin.
Example:
Pin Chamber 1
4 + 10 = 14 14 - 5 = 9
Pin Chamber 2
8 + 10 = 18 18 – 4 = 14
Pin Chamber 3
6 + 10 = 16 16 – 9 = 7
Pin Chamber 4
1 + 10 = 11 11 – 3 = 8
Pin Chamber 5
3 + 10 = 13 13 – 4 = 9
Pin Chamber 6
5 + 10 = 15 15 – 2 = 13
3. To calculate the top pin add the bottom pin and the control pin together and subtract from 23.
Example:
Pin Chamber 1
5 + 9 = 14 23 – 14 = 9
Pin Chamber 2
4 + 14 = 18 23 – 18 = 5
Pin Chamber 3
9 + 7 = 16 23 - 16 = 7
Pin Chamber 4
3 + 8 = 11 23 - 11 = 12
Pin Chamber 5
4 + 9 = 13 23 – 13 = 10
Pin Chamber 6
2 + 13 = 15 23 – 15 = 8
Using the underlined results we have the pinning chart below and this core is ready to key.
Understanding the pinning chart and pinning the core
This pinning chart is set up to key a core. The core is pinned
from the back to front pin. Prior to pinning the core move the
control sleeve to the locked position and turn the plug to the
90 degree position, this will allow you a cross check as you
pin the core.
By using this method when the core is fully pinned each
chamber should be at the same height in the core. In order
to rotate the plug to the ninety degree position a key with the
correct key profile must be inserted in the core to lift the side
pins into place and allow the plug to turn.
The pin stack will be visible when this method is used. It is
good practice to pin each chamber one at a time.
F 14 G
Small Format Cylinder Information
Pinning Chart for change key only core
CK 5 4 9 3 4 2 Control Key 4 8 6 1 3 5
Change Key
5
4
9
3
4
2
MP
5
4
9
3
4
2
CP
9
14
7
8
9
13
TP
9
5
7
12
10
8
When Building a pinning chart it is advisable to keep the control out of the chart as it tends to
confuse the pinning issue.
When setting up a pinning chart for a master keyed cylinder the process is the same with the
addition of the master pins. The math is the same for achieving the control pins as follow:
1. Step one calculate the bottom and master pins
2. Step two add ten (10) to the cut of the control key and subtract the bottom pin and
master pin from this number to achieve the control pin. The cut of the control key plus
ten is known as the control number.
MK 5 9 8 1 0 1
CK 5 3 4 3 4 5
Control Key 4 3 5 8 3 4
Control pin calculations
Example:
Pin Chamber 1
Pin Chamber 2
Pin Chamber 3
Pin Chamber 4
Pin Chamber 5
Pin Chamber 6
Top pin calculations BP + CP
4 + x + 10 = 14 - 5 = 9
Control number
BP+MP
3 + 10 = 13 13 - 9 = 4
3+6=9
5 + 10 = 15 15 –8 = 7
4+4=8
8 + 10 = 18 18 – 3 = 15
1+2=3
3 + 10 = 13 16 – 4 = 9
0+4=4
4 + 10 = 14 14 – 5 = 9
1+4=5
Total Stack – Control Number = Top Pin
F 15 G
Small Format Cylinder Information
Pin Chamber 1
Pin Chamber 2
Pin Chamber 3
Pin Chamber 4
Pin Chamber 5
Pin Chamber 6
5 + 9 = 14
BP + MP + CP
3 + 6 + 4 = 13
4 + 4 + 7 = 15
1 + 2 + 15 = 18
0 + 4 + 9 = 13
1 + 4 + 9 = 14
23 – 14 = 9
23 - 13 = 10
23 - 15 = 8
23 – 18 = 5
23 – 13 = 10
23 – 14 = 9
Master Key
5
9
8
1
0
1
Change Key
5
3
4
3
4
5
BP
5
3
4
1
0
1
MP
X
6
4
2
4
4
CP
9
4
7
15
9
9
TP
9
10
8
5
10
9
There is another way to do these calculations that is easier however it important that everyone
know the basic math prior to learning the other process. If you note that the cut of the control
key and the top pin add up to 13 in every case then it would be easier to calculate the top pin
and insert the tops in the chart as they will not change for every core with that control key. The
method for calculating the top pin now becomes sub tract the cut of the control key from 13 to
obtain the top pin.
Example:
13
13
13
13
13
13
-4
-3
-5
-8
-3
-4
9
10
8
5
10
9
Once the bottom pin, master pin and top pin numbers are known add together and subtract
them from 23 to get the control pin.
To pin the core:
1. Place core in front of you with the plug face to your right, the control sleeve in the locked
position and the plug turned to 90 degrees.
2. In the chamber to the back of the core (left hand side of the core) place the bottom pin
Control pin and then the top pin. Repeat for each pin chamber. When the core has all pin
chambers properly pinned the pin stack should be visible and equal in all pin chambers.
3. Rotate the plug to the 0 degree position and insert core in capping block.
4. Insert a spring and cap in each pin chamber and cap.
*** Note when keying this process can be changed to pinning one pin chamber at a time
capping with Allen set screw and checking the core function. Simply repeat the process until the
entire core is keyed and capped.
F 16 G
Tools and Service Kits
Service Kits
CRP HSK HIGH SECURITY ACCESSORY KITS
KITPARTS-1
CAMADAM-1 x 10, CAMYALE-2 x 10, CAMYALE-2A x 10, CAMRUSS-3 x 10 ,
CAMFLCN-4 x 10, CAMSCHL-7 x 10, CAMSGNT-8 x 10, KIKLCAP-01 x10,
KIKLCAP-02 x 10, RIMPACK x 2, KIKLZTP-01 x 5, KIKLZTP-02 x 5,
KIKLZTP-03 x 5, KIKLZTP-04 x 5, KIKLZTP-05 x 5, KIKLZTP-06 x 5,
LZTPDD-BLK x 20, LZTPDD-GLD x 20, LZTPSD-01 x 10
KITSTDPIN- 2
ALLNSCRW-SS x 25, ALLNSCRW-BLK x 25, KIKPINSPRING x 100, KIKSPRING x 25,
CAMSCREW x 25, SIDEBAR-1 x 10, MSHRMTPIN x 50, KIKPIN x 25,
SPIN1 x 10, SPIN2 x 10, SPIN3 x10, SPIN4 x 10,
TPWASHER x 10, SIDEBARSPRING x 20
F 17 G
Tools and Service Kits
KITULPIN -3
SSBPIN1 x 24, SSBPIN2 x 24, SSBPIN3 x 24, SSBPIN4 x 24, SSBPIN5 x 24,
SSBPIN6 x 24, SSBPIN7 x 24, SSBPIN8 x 24, SSBPIN9 x 24,
ULMSHRMTPIN x 50, ALLNSCRW-SS x 25
KITULPIN -4
SPIN1 x 20, SPIN2 x 20, SPIN3 x 20, SPIN4 x 20, TPWASHER x 20,
F 18 G
Tools and Service Kits
KIKPIN x 25, KIKSPRING x 25, ALLNSCRW-SS x 25, ULMSHRMTPIN x 100,
SIDEBARSPRING x 20, SIDEBAR-1 x 10
KITSFICPARTS-5
SFICSPIN1 x 20, SFICSPIN2 x 20, SFICSPIN3 x 20,
SFICCCLIP x 25, SFICPSPR x 50,
SFICSIDEBAR x 10, SFICSBSPR x 25, SFICALLNSCRW x 25
KITCAMS-6
LFCAMADAM-1 x 5, LFCAMFLCN-4 x 5, LFCAMRUSS-3 x 5, LFCAMSCHL-7 x 5,
LFCAMSCRW x 30, LFCAMYALE-2 x 5, LFCAMYALE-2A x 5, MRTPINSPRING x 50,
ULCAMADAM-1 x 5, ULCAMFLCN-4 x 5, ULCAMRUSS-3 x5, ULCAMSCHL-7 x 5,
CAMSCREW x 25, ULCAMSGNT-8 x 5, ULCAMYALE-2 x 5, ULCAMYALE-2A x 5,
CAMADAM-1 x 5, CAMYALE-2 x 5, CAMYALE-2A x 5,
F 19 G
Tools and Service Kits
CAMRUSS-3 x 5, CAMFLCN-4 x 5, CAMSCHL-7 x 5, CAMSGNT-8 x 5
Tools Needed
1. Pinning Block
2. Stamping Block for Keys
3. Cut off tool for MC / RC drive pins
4. Shear tool for MC / RC drive pins
5. Key Gages
a. Small Format
b. Large Format
Tool Resources
1. Engravers
2. Key Machines
3. Stamping Machines
4. Stamp Sets
F 20 G
Master Keying Cylinders and Keying Systems
Simple Master Key System Set-up Chart
Item #
Heading
Number
Door
Number
Pinning on three pin chambers 16
possible change keys
Master
Lock Type Change Key
Key
F 21 G
Control Key
Special Keying
Notes
Master Keying Cylinders and Keying Systems
Basic Master Key System Set-up Chart
Item #
Heading
Number
Door
Number
Pinning on three pin chambers 64
possible change keys
Change
Master
Lock Type
Key
Key
F 22 G
Control Key
Special Keying
Notes
Master Keying Cylinders and Keying Systems
Basic Master Key System Set-up Chart
Item #
Heading
Number
Door
Number
Pinning on four pin chambers 256
possible change keys
Lock
Change
Master
Type
Key
Key
F 23 G
Control
Key
Special Keying Notes
Master Keying Cylinders and Keying Systems
Grand Master Key System Set-up Chart
Item
#
Heading
Number
Door
Number
Pinning on five pin chambers 1024
possible change keys
Grand
Lock Change Master
Master
Type
Key
Key
Key
F 24 G
Control
Key
Special Keying Notes
Master Keying Cylinders and Keying Systems
Great Grand Master Key System Set-up Chart
Item
#
Heading
Number
Door
Number
Pinning on six pin chambers 4096 possible
change keys 4 GMK with 16 MK with 64 CK
Great
Great
Grand
Lock Change Master
Master Grand
Type
Key
Key
Master
Key
Key
F 25 G
Control
Key
Special Keying Notes
Appendix
APPENDIX
x
x
x
x
x
APPENDIX A – Key cutting key technical information for LFIC
APPENDIX A-1 - HSK cut form / Maximum cut range
APPENDIX B - Key cutting key technical information for SFIC
APPENDIX C – HSK MC/RC Shell - Tail Piece Shears
Sample Dealer Agreement
x
Tool Resources
4
1-323-888-6601
6605 Flotilla Street
2
Commerce, California 90040
Cal-Royal Products
0.387
.231
5
1.011
.855
.699
.543
7
3
All information enclosed in this drawing is confidential and is
not to be reproduced or distributed to other individuals or
companies without the written consent of Cal-Royal Products Inc.
HSK Full Size Keyblank
8
KEY CUTTING TECHNICAL KEY DATA
FOR LARGE FORMAT INTERCHANGEABLE CORE
APPENDIX A
Depth of Cut
.320
.305
.290
.275
.260
.245
.230
.215
.200
.185
12 August 2013
Revision
A
0
1
2
3
4
5
6
7
8
9
1-323-888-6601
6605 Flotilla Street
Commerce, California 90040
Cal-Royal Products
Key Cut 598101
.035
7
0
7
7
All information enclosed in this drawing is confidential and is
not to be reproduced or distributed to other individuals or
companies without the written consent of Cal-Royal Products Inc.
HSK Cut Form / Maximum Adjacent Cut Range
Can not be cut and work
8 Differance
8 0
Maximum adjacent cut
7 Differance
APPENDIX A-1
Drawn By Bill
Date 9 July 2013
Scale 2.5 : 1
0
9
1-323-888-6601
6605 Flotilla Street
Commerce, California 90040
Cal-Royal Products
.053
9
2
5
3
0.8360
0.6860
8
0.9860
7
6
A
0.5360
0.3860
0.2360
0.0860
All information enclosed in this drawing is confidential and is
not to be reproduced or distributed to other individuals or
companies without the written consent of Cal-Royal Products Inc.
HSK Small Format Interchangeable Core Key Data
4
KEY CUTTING TECHNICAL KEY DATA
FOR SMALL FORMAT INTERCHANGEABLE CORE
APPENDIX B
Depth of Cut
.3170
.3045
.2920
.2795
.2670
.2545
.2420
.2295
.2170
.2045
Drawn By Bill
Date 13 May 2013
Revision 1
A
0
1
2
3
4
5
6
7
8
9
1-323-888-6601
6605 Flotilla Street
Commerce, California 90040
Cal-Royal Products
All information enclosed in this drawing is confidential and is
not to be reproduced or distributed to other individuals or
companies without the written consent of Cal-Royal Products Inc.
HSK MC/RC Shell
APPENDIX C
Drawn By W.A Deahl
Date 10 May 2013
Revision
CRP SECURITIES DEALER SERVICE CENTER AGREEMENT
This agreement has been reached on this ___ day of __________________, 20__ between Cal-Royal
Products, Inc. (“CRP Securities”) located at 6605 Flotilla Street, City of Commerce, CA 90040 and
______________________________________________________________ (“Dealer”), located at
_________________________________________________________________________________.
Whereas, CRP Securities has the exclusive intellectual, marketing and sales rights to several product lines
of high security locks, cylinders and keys with restricted duplication, and
Whereas, one such product line is known as CRP High Security System, and
Whereas, Dealer desires to become a non-exclusive source for sales and service center of the CRP HSK
High Security Key System. CRP Securities agrees to have Dealer become such a source. Both parties
agree as follows:
1. Sales and Services
1.1 CRP Securities appoints Dealer to operate a non-exclusive restricted key/lock service center from
which CRP High Security System products and services are provided, subject to all the terms and
conditions set forth herein. Dealer agrees that this appointment does not imply or grant any right of
access to any other CRP Securities products or key sections.
1.2 Dealer agrees that its appointment as a source of CRP High Security System products does not
constitute appointment as a locksmith supply distributor, alarm supply distributor, or supplier of
CRP High Security products for resale, and Dealer agrees not to act in such capacity. Dealer shall
confine its efforts to sales of CRP High Security System products to customer accounts and its use
within the United States.
1.3 Dealer will only use approved and properly maintained key cutting and assembly equipment on the
CRP High Security System. Dealer will therefore instruct all of its employees and customers as to
the proper procedure involved in the use of CRP High Security System and will display only
literature or signage about the CRP High Security System with prior approval from CRP Securities.
1.4 Dealer agrees not to sell, distribute or lend uncut, 0 bitted, 1 bitted, or 2 bitted CRP High Security
key blanks to anyone other than CRP Securities under any circumstances. Dealer also agrees not
to alter or modify in any form the CRP High Security System products to operate in cylinders other
than those for which they were intended and for which Dealer is authorized.
1.5 Dealer agrees to immediately notify CRP Securities of attempted sales of CRP High Security Key
blanks by a party other than CRP Securities or its authorized distributor, any attempt to obtain
CRP High Security key blanks without proper authorization, and any shortage in the CRP High
Security key blank inventory which Dealer discovers at any time.
1.6 Dealer agrees to cut additional keys only for Restricted Section keys system supplied by service
center or when authorized in writing by CRP Securities to act as field service agent for designated
installations.
1.7 Dealer agrees to notify all potential customers of CRP High Security System products, prior to
purchase, of its proprietary nature, and that the customer may be required to return to the Dealer
for any additional future service. Dealer must thereby enable the customer to make an informed
decision about the level and nature of key control it is selecting.
6605 Flotilla St.
City of Commerce, CA 90040 U.S.A
Tel: 323.888.6601 1-800-876-9258
Fax: 323.888.6699 1-800-222-3316
1
Website: www.cal-royal.com
Email: [email protected]
1.8 The dealer agrees to actively promote the CRP Securities High Security Cylinder Program. The
dealer within the confines of this agreement may use advertising material provided and approved
by CRP Securities to promote the program.
2. Financial Policies
2.1 Dealer agrees to purchase CRP Securities products at a minimum value of Two Thousand Five
Hundred Dollars ($2,500) during the first twelve (12) months of the term of this agreement, at a
minimum value of Five Thousand Dollars ($5,000) for each twelve (12) months thereafter. CRP
Securities reserves the right to modify this volume requirement as necessary to accommodate
inflation, price increases and improved sales opportunities in Dealer’s territory; Dealer will be given
thirty (30) days written notice of any new purchase volume requirement.
2.2 Dealer agrees to abide by the payment terms and financial policies as specified by CRP Securities
or its authorized distributor from time to time.
2.3 This agreement includes only the provisions stated herein and does not infer or allow a franchise
or partnership of a financial nature between the Dealer and CRP Securities . The dealer is
responsible for all management and financial actions of the Dealers business and shall hold CRP
Securities separate and harmless from its financial interests.
3. Key Control
3.1 Dealer agrees under no circumstances will he/she cut or duplicate any key that is not originated
from his/her facility. Non-compliance can result in immediate cancellation and/or termination of the
dealer agreement.
3.2 All CRP High Security System key blanks furnished to Dealer by CRP Securities shall have the
CRP Securities brand name coined on one side of the bow and the Dealer’s name identified on the
opposite side of the bow. Dealer agrees to cut and furnish keys for CRP High Security System
cylinders on CRP Securities original manufactured blanks only.
3.3 Dealer agrees to Provide CRP Securities a duplicate record of all CRP High Security Key Systems
using the section created by the Dealer and to update such records as changes become
necessary.
Records to be forwarded to:
CRP High Security Systems Manager
6605 Flotilla
Commerce, Ca. 90040
3.4 Dealer agrees to enforce all appropriate measures to guaranty safety and security of the CRP
High Security System key blanks, key records and CRP High Security System cutting machine,
which measures shall as a minimum include but not limited to (1) properly securing the CRP High
Security System key cutting machine to ensure that its use is restricted to those individuals who
are authorized by Dealer; and (2) securing under lock and key or vault the CRP High Security
System key blanks and key records to ensure that access to them is limited to those individuals
authorized by Dealer.
3.5 Dealer assumes full responsibility for protection of the CRP High Security System key blanks and
for the cutting of the same. Dealer agrees to be responsible for assuring that each of its
employees and representatives comply with the provisions of this Agreement.
3.6 Dealer agrees that all proprietary information regarding the CRP High Security Systems is the
property of CRP Securities and is not to be disclosed or transmitted in any manner to other
organizations, manufacturers or competitors of CRP Securities.
6605 Flotilla St.
City of Commerce, CA 90040 U.S.A
Tel: 323.888.6601 1-800-876-9258
Fax: 323.888.6699 1-800-222-3316
2
Website: www.cal-royal.com
Email: [email protected]
4. Contract Termination
4.1 Either party may terminate this Agreement with or without cause, for any or no reason, upon thirty
(30) days written notice to the other party. If one party defaults in the performance of any
obligation thence, the other party shall have the right to terminate this agreement effective
immediately upon notice of the defaulting party, regardless of the reason therefore.
4.2 Upon notice of termination, CRP Securities will discontinue shipment of CRP High Security key
blanks to the Dealer. Upon such termination, the parties agree that CRP Securities shall have the
option to repurchase from Dealer any CRP Securities key cutting machine, all CRP High Security
key blanks, and any CRP High Security System products at the purchase price paid by Dealer. In
addition, Dealer shall immediately forward to CRP Securities all copies of records relating to the
CRP High Security restricted key sections, including but not limited to key bitting lists, key
issuance records, authorizations, signature records, customer records, and receipts. If such
records and restricted section blanks are not provided within fifteen (15) business days of such
termination, CRP Securities may proceed to take all steps necessary to obtain or reconstruct this
material and/or information and all costs, including attorneys’ fees, shall be borne fully by the
Dealer.
4.3 The failure of either party to require the performance in whole or in part, of any term of this
Agreement, shall not prevent a subsequent enforcement of such term or breach thereof nor be
deemed a waiver of any subsequent breach.
4.4 The term of this Agreement is for an indefinite period beginning with the effective date in which
CRP Securities signs the Agreement, and ending with the termination provided of this Agreement.
4.5 This agreement between CRP Securities and the Dealer shall constitute the complete working
understanding between both parties. The dealer may not transfer this agreement to another
individual, organization or entity.
This agreement may not be modified without written
authorization of both parties and such written agreement shall be with a minimum of thirty days
notice unless otherwise specified in the amendment. If any portion of this agreement is ruled to be
violation of a law or code the balance of the agreement shall remain in full force.
5. General Conditions
5.1 Dealer agrees to indemnify and hold CRP Securities harmless against any losses or damages,
including reasonable attorneys’ fees and expenses, which CRP Securities may suffer as a result of
Dealer’s impropriety, negligence, or breach in performing its obligations as stated in the
Agreement.
5.2 This agreement is binding upon both parties and is subject to the statutory laws of the State of
California, City of Los Angeles and state of ___________________________.
5.3 Both parties confirm that they have read and understood this Agreement and undertake to abide
with it. This Agreement may not be modified or amended in any way without the prior written
consent of both parties. Dealer shall not have the right to assign this Agreement in whole or in part
without CRP Securities’ prior written consent.
6605 Flotilla St.
City of Commerce, CA 90040 U.S.A
Tel: 323.888.6601 1-800-876-9258
Fax: 323.888.6699 1-800-222-3316
3
Website: www.cal-royal.com
Email: [email protected]
IN WITNESS WHEREOF, the parties have executed this Agreement in duplicate, each of which shall be
considered an original as of the date shown next to each signature.
DEALER
Date: ___________________________
By: _________________________________
Print Name: __________________________
Title: ________________________________
CAL-ROYAL PRODUCTS, INC.
Date: ___________________________
By:_________________________________
Print Name:___________________________
Title:________________________________
6605 Flotilla St.
City of Commerce, CA 90040 U.S.A
Tel: 323.888.6601 1-800-876-9258
Fax: 323.888.6699 1-800-222-3316
4
Website: www.cal-royal.com
Email: [email protected]