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blers. Each of these variations can extend the range, flexibility, and security of the system. A locksmith must be conversant with all of them.
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Keyway variations
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Figure 9.11 illustrates a system of control based on keyway design. General Lock s Series 800 key section passes all cylinders in the system; 29, 30, 31, 32, and 33 are submasters, each passing four cylinders; the change keys are restricted to their own individual cylinders. In its fullest expansion, the system includes 35 different keyways on the change-key level and four master key levels.
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High-security pin tumbler cylinders
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Figure 9.12 illustrates features of the General lock:
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100 key bitting for long wear (A). Master pins have a minimum length of 0.040 inch (B). Shorter pins tend to wedge in the chamber. Only two pins are standard (C). Pins and springs are made of corrosion-resistant alloy (D and E). The keyway is part of the security system (F). If requested, the factory supplies special identification for keys, cores, and cylinders (G).
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Figure 9.11 A keyway system developed by the General Lock Company.
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The Emhart (Corbin) High-Security Locking System uses rotating and interlocking pins (Fig. 9.13). The pins must be raised to the shear line and, at the same time, rotated 20 so the coupling can disengage (Fig. 9.14 and 9.15). Rotation is by virtue of the skew-cut bitting on the key (Fig. 9.16). Figure 9.17 illustrates the way the cylinder is armored. The pins are protected by hardened rods and a crescent-shaped shield.
Removable-core cylinders
Removable-core cylinders are increasingly popular. Figure 9.18 illustrates the Corbin cylinder, a type typical of most. To rekey the change key, follow this procedure: 1. Obtain a Corbin rekeying kit. The kit includes the necessary pins, gauges, and tools.
Figure 9.12 General locks have
special features described in the text.
Figure 9.13 Corbin s High-Security
Locking System depends on split and rotating pins.
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Figure 9.14 Pins are rotated in
either direction to allow the joint to uncouple. (Emhart Corp.)
Figure 9.15 Pins must be rotated and brought to the shear line for the lock to open.
Figure 9.16 The Corbin key has a
bitting cut at 20-degree angles.
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Figure 9.17 Passive defense measures include hardened steel pins and armor plate. (Emhart Corp.)
Figure 9.18 Corbin removable core cylinder.
2. Mount the cylinder in a vise. 3. Remove the plug retainer. 4. Select as the plug extractor the key with the deepest bitting. Normally, the grand master key meets this specification; however, there are instances where the engineer s key will have the deepest bitting. A shallow-cut key complicates matters by forcing the control pins, drivers, and buildup pins into the cylinder. 5 Withdraw the plug and remove all pins from their chambers. Figure 9.19 illustrates this procedure.
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6. Determine the bitting of the change key. 7. Write down the new combination. As an example, suppose the original change-key bitting is 513525 and we wish to reverse it to 525315 (Fig. 9.20). 8. Install the tumbler pins, ball end down. 9. Use a depth gauge to determine the master key bitting. 10. Calculate the master pins by subtracting the change-key bitting combination from the master key combination. If the master key combination was 525763, the difference between it and the new change-key combination would be 448. 11. Insert the master key into the plug. 12. Install the appropriate master pins (Fig. 9.21). 13. Remove the master key carefully and insert the grand master key. Select the master split pins by subtracting the master key bitting from the grand master key bitting. All pins should be flush with the surface of the plug.
Figure 9.19 Using the appropri-
ate follower, remove the plug, then dump the pins. (Emhart Corp.)
Pin length corresponds to the change-key combination. (Emhart Corp.)
Masterkeying
Figure 9.21 Subtract the changekey combination from the master key combination. The difference represents the length of the master pins. (Emhart Corp.)
14. Assemble the plug and cylinder. 15. Test all keys. 16. Lubricate the keyway with a pinch of powdered graphite.
Master-ring cylinders
The Corbin master-ring cylinder is shown in Fig. 9.22. The change key operates the plug plungers, and the master key operates the plunger in the master ring. Sometimes called two-in-one cylinders, these cylinders increase the range of key combinations for any given system. To rekey the change key, follow this procedure: 1. Mount the plug in a vise and remove the cylinder slide with a pair of pliers or a small chisel. 2. Remove the springs, drivers, and pins (Fig. 9.23). 3. Ream pin holes through the shell, master ring, and plug (Fig. 9.24). 4. Assuming that the original combination was 414472, reversing the combination gives 274414. This will be the combination of the new change key. 5. Reverse the pins to conform with the new combination. That is, the pin that was first goes into the last chamber; the pin that was second goes in to the fifth chamber, and so on. 6. As you install each pin, tamp it home with a drill bit and turn the key. If the key will not turn, you have confused the pin sequence. 7. Assemble the lock and test. To rekey the master key, follow this sequence: 1. Mount the cylinder in a vise and remove the cylinder slide with a pair of pliers or a small chisel. 2. Remove the springs, drivers, and pins. 3. Determine the master key bitting with a gauge. The combination runs from the shoulder to the tip of the key, the reverse of the usual sequence. As an example, let it be 678572.
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