KEYS/TOOLS

Tools for Servicing Interchangeable

Cores
Specialized IC tools help locksmiths service or recombinate cores, determine pin lengths, cap the
pin chambers and cut and decode keys.

Author — Jerry Levine

Jun 4th, 2012

The small-format interchangeable core (IC) is regarded as the “universal” lock mechanism
throughout the commercial door hardware industry. Servicing interchangeable cores
require specialized tools to ensure smooth operating locks and keys, than conventional lock
cylinders. The core tolerances are much tighter. The pin diameter is smaller, .108” diameter
versus .115” diameter for conventional lock cylinders. To cut a key requires a 90-degree
included angle cutter, and cores are not as forgiving as conventional lock cylinders.

Just some background information: Best developed the A2, A3 and A4 systems to provide
expanded keying options when setting up their interchangeable core systems. The A2
system is based on a .0125” increment between the pins lengths. The A3 system is based on
a .018” increment. The A4 system is based on a .021” increment.

For this article, unless otherwise specified, I will be discussing interchangeable core
products based on the Best A2 system. When discussed, I will list manufacturers
alphabetically.

Manufacturers of interchangeable cores include Arrow, Best Access, Best Security, Corbin
Russwin, CX-5, DORMA, Falcon Lock, GMS, Ilco, KSP, Medeco, Mul-T-Lock, PDQ, Sargent
Lock, Schlage Lock, Ultra Security and Yale Lock.

Some of these manufacturers offer higher security and patented key control. These
specialized cores are manufactured to the basic outside dimensions allowing
interoperability between manufacturers interchangeable core lock housing products. For
example, Medeco has KeyMark Interchangeable Core. CX-5 has the Waved Security Groove.
Schlage has the Everest.

Depending upon the manufacturer and the key material, there are three different pin types
for interchangeable cores.

1. Flat nose, nickel silver material pins designed specifically for Best Interchangeable
Cores.
2. Nickel silver material with the radius blended into a +/- .015” flat nose for all other
interchangeable cores except BEST. 
3. Brass IC pins with a radiused nose for Interchangeable Cores that will be operated
with brass keys.

The pin shapes and composition materials affect the operation and life expectancy of
interchangeable cores and the keys. The recommendations are to use brass bottom pins
when the cores are operated by brass keys. Use nickel silver bottom pins when using nickel
silver keys. This will optimize the life expectancy of the keys and the cores. Top pins, build-
up pins and master pins are normally brass.

Pinning kits are available from the core producers and LAB. LAB offers different styles of
rekeying kits including steel, wood and polyethylene containing varying quantities of pins.
The bottom pins are brass or nickel silver depending upon the kit.
Early Best and Falcon manufactured interchangeable cores used a plate-style spring
retainer like most conventional mortise cylinders to retain the springs and pins in each pin
chamber. Over time, the design changed to individual pin chamber caps, eventually
replacing the plate style spring retainer.

There are two different sizes of pin chamber caps for interchangeable cores. Stamped pin
caps are .1185” diameter and machined pin caps are .117 +/- .0005 diameter. Stamped pin
caps are manufactured of a softer brass.

SPECIALIZED TOOLS
Specialized tools are required to service or recombinate the core. There are tools that are
single function such as loading, unloading or capping the pin chambers. Unloading tools,
commonly known as “Dump” Tools, operate with an ejector pin. These products are
designed to remove the pin chamber caps, permitting the springs and pins to be removed.
Some have an attachment that captures the content of each pin chamber unloads
separately and in order. This permits decoding the pins to determine the operating key
depths of cut and the  top master key depths of cut, as well as decoding the control key
bitting.

Loading (block) tools hold the cores in place as the pins are loaded into the pin chambers. It
is important to always load one pin chamber, test the operation with the operating key, top
master key and the control key. If the three keys operate the core, then load the next pin
chamber. This way, if one pin chamber does not operate, you do not have to completely
unload the core in order to fix the problem.

Coding an interchangeable core requires knowing the top level master key, the operating
key and the control key depths of cut. From the three keys, the bottom pin, master pin,
build-up pin and the top pin lengths are determined.

Determining Pin Lengths

There are three ways to determine the pin lengths, using the lengths of the pins or the pin
numbers. For example, the A2 system has a total stack height of 23 or .397”.

Here are the formulas necessary in order to determine each pin stack:

Control Key Depth of Cut + 10 - Plug Total = Build-Up Pin

Plug Total = Length of the Bottom Pin + the Master Pin (if applicable)

Plug Total + Build-Up Pin subtracted from 23 = Top Pin

Plug Total + Build-Up Pin + Top Pin =23  

FYI: The Best A2, A3 and A4 Systems each have a specific value for their pin stacks. The A2
System has a pin stack value of 23. The A3 System has a pin stack value of 16. The A4 System
has a pin stack value of 14.

The Ultra Security "QU-I.C-KEY" pin segment calculator contains 16,384 pin segment
calculations for a complete dedicated A2 Grandmaster System. It has seven chamber
wheels, with each wheel having six sections. Each section indicates a key cut and displays
the proper pin segments – (bottom pin, master pins, control pin and build-up pin) for that
cut.

LAB offers the EASY WAY I.Core Pinning Slide Chart for A2 System, part number LSC001.
This slide chart displays pin stacks for one pin chamber at a time. The top master key cut
and the control key cut are positioned. Align with the change key depth and the pin lengths
are indicated for master keyed and non-master keyed A2 System pin chambers.

The Ultra Security "QU-I.C-TEST Tool”, part number QTT and "QU-I.C-TEST Adapter", part
number QTA, are used to verify that the core is properly combinated. The core is inserted
into the "QU-I.C-TEST Adapter" once it has been combinated. The "QU-I.C-TEST Tool”
spring loaded brass rods press down into the pin chambers simulating a capped core. The
top master key, operating key and control key are tested. Testing will confirm if the core has
been properly combinated. The trumpet keys will indicate if any chambers are “hanging up”
(shelf problem) when the keys are withdrawn from the core.  Inserting a key blank enables
comparing all the chambers and determines where the differences are and make the
appropriate corrections.

Once the cores have been combinated and tested, the final step is to cap the pin chambers.
Capping tools are designed to secure the core while installing the cap. The standard loading
tool has a cut-to-cut spacing of .150”. Before capping, look into the tool to be certain the pin
chambers align with the tool’s openings.

There are two methods for capping the individual pin chambers: individual capping blocks
where one cap is secured into a pin chamber and capping presses that cap all of the pin
chambers at one time.

A1 Security offers two styles of capping presses. The CapSaver Press, part number CAP-5,
uses a brass strip to form the caps and caps all of the chambers in one operation. Forming
the caps eliminates the need to position individual caps onto each pin chamber. The
Capping Press Plus, part number CAP-1, caps interchangeable cores and has a separate
attachment for dumping.

Combination tools can perform unloading, loading and capping. For example, the LAB
Interchangeable Core Annex® that has a slide out code book into which each pin chamber
pins, springs and cap unloads. The Pro-Lok® LT340 IC Rekey/Decode/Dump Tool features
a removable pin dump receptacle capping cover.

CUTTING IC KEYS
Cutting interchangeable core keys can be difficult. The key blades are thin and when
secured with a standard rotary key originating machine vise, they can be secured using too
much pressure. This is because the blades are thin and irregularly shaped. Extra force is
often exerted out of frustration and in the hope to keep the key blank in proper position in
the vise as it is being cut. This problem can also occur when duplicating interchangeable
core keys.

This pressure results in the key blade spreading out and becoming misshapen. Under the
compression of the key vise, the blade can grow a few thousandths of an inch. Once cut and
removed from the vise jaws, the depths of cut in the blade under compression will attempt
to reform, resulting in incorrect cuts in the key.

Using a key punch machine designed to originate the interchangeable core keys can
eliminate these problems.  The key punch machine vise jaw is designed specifically for
interchangeable core keys. In addition, the cutter is specifically designed for the origination
procedure, having the correct flat and fixed depths and spacing. Standard spacing for
interchangeable cores is .150” cut-to-cut. Some security products have different spacing.

The following is a list of interchangeable core key punch machines:

A1 Security Manufacturing PAK-1C handheld key punch machine

A1 Security Manufacturing Mean Green Machine GP201-A2
Best Combinator
Pro-Lok BP201IC
Rytan RY2000 A2

Before purchasing a punch machine,  make sure the vise jaws are designed to secure the
keyway you plan on originating keys. For example, the Pro-Lok BP201IC will originate keys
for the A2 System using the A-R, TA-TE and W key blades. The A1Security Manufacturing
PAK-1C, Pro-Lok BP201IC and the Rytan RY2000 IC punch machines can be modified to
originate A3 and A4 system keys.

Many years ago, Best sold an older style punch machine for the A2, A3 and A4 systems. They
were color-coded for easy identification. The A2 system punch machine is red. The A3
system punch machine is green. The A4 system punch machine is orange.

KEY BLANKS & DECODERS

IC key blanks are available from core producers and aftermarket key blank manufacturers.
There are more than 30 known keyways manufactured for Best key systems. In addition,
other manufacturers offer their own keyways. Depending upon the aftermarket key blank
manufacturer, key blanks can be available in different configurations including the standard
head and with “Do Not Duplicate” marked into the head. Note: The “Do Not duplicate” key
blank marking is not legally binding in many parts of the world.

Key decoders are metal plates with one or more reducing slot used to determine the depths
of cut in a key. The key is inserted into the slot along one of the cuts flat. As the key slides,
the slot becomes smaller, eventually indicating the depth of cut. Interchangeable core key
decoders are available in different configurations. Some have only a single slot, while others
have three slots for the A2, A3 and A4 Systems.

Once the cores have been installed, occasionally the control key is no longer available. This
results in having to remove a core in order to determine the control key bitting.

A core can be removed several ways. Picking the core to the control shear line is a non-
destructive method. However, using standard turning (tension) tools, there is no guarantee
the core will be picked to the control shear line. Specialized turning tools that have one or
more tabs can be used to pick to the control shear line. Each pin chamber in an
interchangeable core has openings from the top to the bottom. Using a turning tool with a
tab that extends into the lug sleeve puts turning pressure on the control shear line. To pick
the control shear line, use clockwise turning pressure.

There are several manufacturers of interchangeable core turning tools. Peterson

Manufacturing offers three styles of IC tension tools, the differences being the thickness of
the tool and the keyways they will accommodate. The Type A Tension Tool is designed for
the A, C, DD, M, TR, Q, and R keyways. The Type B Tension Tool is designed for the D, B, E, F,
G, H, K, and N keyways. The Type C Tension Tool is designed for the wider keyways, such as
the E style. Note: When using these tools, insert a wood toothpick into the bottom of the
keyway behind the tool to affix the tool in place.

When the core is damaged and the control key will not remove the core, the question
becomes: Do I drill the core or the housing? The destructive decision is determined by
knowing what you need. If the core is mal-functioning, drill the core. If the housing is
expensive, drill the core. To determine the control cuts, it is easier to drill the housing.
When drilling the core, remember it is a one time operation.

Drill jigs are available for drilling interchangeable cores. Should you decide to drill, make
sure the jig uses drills for the location and size of hole you want. The Peterson
Manufacturing IC-DJ, I-Core Drill jig for SFIC cores drills the control shear line.

FMI
For more information, contact your local locksmith distributor or the following
manufacturers:

A1 Security Manufacturing. Web Site: www.demanda1.com

Arrow Lock. Web Site:  www.arrowlock.com

Best Access. Web Site:  www.bestaccess.com

Corbin Russwin. Web Site:  www.corbinrusswin.com

CX-5. Web Site:  www.cx5security.com/

DORMA. Web Site: www.dorma-usa.com

Falcon Lock. Web Site:  www.falconlock.com

GMS. Web Site:  www.gmslock.com

Kaba-Ilco Corp. Web Site:  www.kaba-ilco.com/key-systems

KSP. Web Site: www.iccore.com

LAB. Web Site:  www.labpins.com

Medeco. Web Site: www.medeco.com

Mul-T-Lock. Web Site: www.mul-t-lock.com

PDQ. Web Site: www.pdqlocks.com

Peterson Manufacturing. Web Site: www.peterson-international.com

Pro-Lok. Web Site: www.pro-lok.com

Sargent Lock. Web Site:  www.sargentlock.com

Schlage Lock. Web Site: www.schlage.com

Ultra Security. Web Site: http://ultrasecurityusa.com

Yale Lock. Web Site: www.yalelock.com

A2, A3, and A4 Interchangeable Core Pin Sizes and

Dimensions

                                                                                                                                Top Pin, Build-up Pin

&                 Top Pin, Build-up Pin &

Bottom Pin Numbers                       Bottom Pin Sizes                               Master Pin

Numbers                        Master Pin Sizes

A2        A3          A4                          A2          A3          A4                          A2          A3         

A4                          A2          A3          A4

0             0              0                          .110”      .110”      .110”                          -               -              

-                               -               -               -

1             1              1                        .1225”     .128”      .131”                          -              1             

1                              -         *.018”    *.021”

2             2              2                          .135”      .146”      .152”                          2              2             

2                          .025”      .036”      .042”

3             3              3                        .1475”     .164”      .173”                          3              3             

3                        .0375”     .054”      .063”
4             4              4                          .160”      .182”      .194”                          4              4             
4                          .050”      .072”      .084”

5             5              5                        .1725”     .200”      .215”                          5              5             

5                        .0625”     .090”      .105”

6             6              -                          .185”      .218”          -                              6              6             

6                          .075”      .108”      .126”

7             -               -                         .1975”         -               -                              7              7             

7                        .0875”     .126”      .147”

8             -               -                          .210”          -               -                              8              8             

8                          .100”      .144”      .168”

9             -               -                         .2225”         -               -                              9              9             

9                        .1125”     .162”      .189”

                                                                                                                              10           10          

10                         .125”      .180”      .210”

                                                                                                                              11           11          

11                       .1375”     .198”      .231”

                                                                                                                              12           12            

-                          .150”      .216”          -

                                                                                                                              13           13            

-                         .1625”     .234”          -

                                                                                                                              14             -              

-                          .175”          -               -

                                                                                                                              15             -              

-                         .1875”         -               -

                                                                                                                              16             -              

-                          .200”          -               -

                                                                                                                              17             -              

-                         .2125”         -               -
                                                                                                                               18             -              
-                          .225”          -               -

                                                                                                                              19             -              

-                         .2375”         -               -

*.018” and .021” master pins are usually not used because they are smaller than .023”, the
accepted value for a single step progression. 

Source URL: https://www.locksmithledger.com/keys-tools/article/10705790/tools-for-servicing-

interchangeable-core-locks