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Retainer screw Retainer nut
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(Rear) Cylinder (Front) Cylinder retainer Key
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Figure 12.13 Exploded view of a laminated Master padlock. (Master Lock Company)
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Removing and replacing the cylinder in solid-body padlock (Nos. 220, 230)
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1. Follow Steps 1 and 2 of Removing and Replacing the Laminated and Pro Series Cylinder. 2. Slide the cylinder retainer out (Fig. 12.14). Turn the retainer upside down to remove the cylinder. 3. Place the new cylinder with the rear end facing up into the retainer. Slide the retainer into the padlock body. 4. Tighten the retainer screw with a hex wrench.
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Rekeying the Pro Series cylinder
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1. Examine the rear of the cylinder and note the flat indent on the otherwise round rim of the cylinder shell. This is the index mark. While holding the cylinder, insert the key and rotate it 90 toward you (counterclockwise) so the bottom of the keyway lines up with the index mark. Caution: Don t rotate the keyway 180 or the pins may jam. 2. Line up the cylinder assembly tool shoulder to shoulder with the rear end of cylinder. 3. Carefully push the tool into the cylinder until the plug comes out. Leave the tool inserted in the cylinder shell to prevent top pins and springs from falling out.
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Keyed Padlocks
Shackle Hex wrench
Retainer screw
Case (Rear) (Front) Cylinder
Cylinder retainer
Figure 12.14 Exploded view of a solid-body Master padlock. (Master Lock Company)
4. Remove the key and turn the plug upside down so that bottom pins drop out. 5. Using a key cut gauge, determine the bottom pin sizes to match the new key cut. 6. Insert pins with pointed side down into the plug. 7. Insert the new key. Each pin should be flush with the plug surface. 8. Slowly push the plug back into the cylinder shell to force the assembly tool out the opposite end. 9. Carefully rotate the key 90 away from you (clockwise) back to the starting position. Caution: Don t rotate the keyway 180 or pins may jam.
Removing and replacing the Pro Series shackle
1. Follow steps 1 and 2 of Removing and Replacing the Laminated and Pro Series Cylinder. 2. Remove the retainer door and nut. Slide the cylinder out. 3. Close the shackle. 4. Strike the bottom of the lock against the palm of your hand. The shackle extension and ball bearings will drop out. 5. Pull up on the shackle to remove it. 6. Insert the new shackle into the lock body.
Twelve
7. To replace the ball bearings, turn the padlock upside down. Drop one ball bearing into the opening. Add a small amount of grease to lubricate if necessary. Use a hex wrench to carefully push the ball into the left channel. 8. Repeat with the other ball bearing, pushing it into the right channel. 9. Replace the cylinder extension with the large steel end in first, lining it up with the opening (make sure the ball bearings stay in either channel). Use a hex wrench to push the extension in as far as possible. 10. Place the cylinder rear end first into the padlock body (remove the key from the cylinder). Replace the cylinder retainer door and nut. 11. Use the key to open the lock and pull up on the shackle. 12. Insert the retainer screw into the shackle opening and tighten with a hex wrench.
ILCO
ILCO secures the cylinder with what the trade calls the loose-rivet method. A single brass rivet extends through the case and into the cylinder. The rivet is headless (hence the term loose) and is secure by virtue of its near invisibility (Fig. 12.15). To remove the pin, follow these steps: 1. Hold the case up to the light and look for the shadow created by the pin. The pin is located 1 8 inch from the bottom of the case and is centered on the side. 2. Using a No. 48 bit, drill a hole in the end of the pin. 3. Thread a small screw into the hole. 4. Gently pry up on the screw and remove it together with the pin. To insert a new pin, follow these steps: 1. Select a piece of brass from stock that exactly matches the diameter of the pin hole. 2. Use the next size smaller rod (to make removal easier if it is ever necessary) and cut it so that 1 32 inch stands out.
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