Mul-t-lock G Series, Service Manual

Page 1: ...Padlock Service Manual ...

Page 2: ......

Page 3: ...Instructions 17 Conversion between Removable Shackle and Pop Open Shackle 19 Pop Open Shackle No 8 20 Disassembly Instructions 21 Cylinder Service 22 Single Pin 23 Disassembly Instructions 24 SBC 13 Sliding Bolt 26 Disassembly Instructions 27 G Series Padlock 30 Padlock G 47 30 Padlock G 47P 31 Padlock G 55 32 Padlock G 55P 33 Padlock G 60 34 G Series Padlock 35 Assembly Instructions 35 Security P...

Page 4: ... Part No Part No Part 1 Padlock body 5 Locking plate 9 Ball St Steel 2 Shackle 6 Bumper 10 Socket head screw 3 Activator cam 7 Identification plate 11 Spring for shutter 4 Body cover 8 Unified shutter 12 Cylinder 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 5: ...Part No Part 1 Padlock body 5 Locking plate 9 Ball St Steel 2 Shackle 6 Bumper 10 Socket head screw 3 Activator cam 7 Identification plate 11 Spring for shutter 4 Body cover 8 Unified shutter 12 Cylinder Protected shackle 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 6: ...k the padlock with the operating key Unscrew one socket head screw 10 using 3 mm allen key Remove locking plate 5 2 Lock the padlock with the operating key Take operating key out and remove body cover 4 2 Protected shackle Disassembly Instructions 1 5 10 ...

Page 7: ... E Series Padlock 3 Remove shutter spring 11 and shutter 8 4 Remove cylinder 12 activator cam 3 and two ball bearings 9 5 Remove shackle 2 5 Protected shackle Disassembly Instructions 8 11 3 4 12 9 3 ...

Page 8: ... NOTE Pay special attention to shackle position height and rotation 2 Insert two ball bearings 9 Insert activator cam 3 in shown position NOTE Activator cam 3 is not symmetrical See diagram 3 A Protected shackle Assembly Instructions 9 3 2 Smaller groove toward the longer leg of the shackle 1 2 ...

Page 9: ...cylinder 12 Insert operating key and rotate the cylinder until it reaches the right position 4 Lock cylinder 12 and remove operating key Install shutter 8 and shutter spring 11 Protected shackle Assembly Instructions 8 11 4 12 3 ...

Page 10: ...es Padlock 6 Install body cover 4 7 Insert operating key and unlock shackle 2 Install locking plate 5 Using 3 mm allen key tighten the socket head screw 10 7 Protected shackle Assembly Instructions 4 6 5 10 2 ...

Page 11: ... Pin 2 Cylinder front cover 9 Ball bearing 5 mm 16 Bolt pusher 3 Ball bearing 4 mm 10 Latch hole plug 17 Plastic bumper 4 Shutter spring 11 Spring 18 Bolt stopper 5 Shutter 12 Latch 19 Socket set screw with cone point 6 Cylinder 13 Lock body 20 Spring for bolt stopper 7 Socket set screw with cone point 14 Spring 21 Bolt Sliding Bolt SBE ...

Page 12: ... with operating key Mount on the bolt disassembling ring and remove the bolt 21 by pulling it out 2 Take out pin and spring 18 20 Using screwdriver push the bolt pusher 16 until the latch 12 pops up Take out the key 1 Sliding Bolt SBE Disassembly Instructions 2 18 20 1 16 ...

Page 13: ...til the cylinder cover can be removed Do not disassemble completely Remove cylinder front cover 2 shutter spring 4 and shutter 5 Take out cylinder 6 and activator cam 8 4 Note It is not needed to disassemble the locking mechanism for re keying Assembly tip Check that the mechanism works properly before inserting the bolt Sliding Bolt SBE Disassembly Instructions ...

Page 14: ...hutter 5 Place cylinder front cover 2 using 2 5 mm allen key tighten screw 19 2 Install pin and spring 18 20 Push them back with a screwdriver until the shackle is inserted Insert key and check for smooth operation NOTE you may need to push bolt pusher 16 in order to turn the key Sliding Bolt SBE Assembly Instructions 18 20 1 16 2 ...

Page 15: ... Series Padlock Removable Shackles 10 13 16 No Part No Part No Part 1 Key 6 Short latch 11 Hive 2 Shell 7 Latch spring 12 Dust shutter 3 Shackle 8 Core 13 Dust shutter spring 4 Long latch 9 Set screw M5 5 Thrust plate 10 Plug Removable Shackles 10 13 16 ...

Page 16: ...3 12 5 7 6 4 2 1 Unlock the padlock with the operating key Using a 2 5 mm allen key remove the set screw 9 Remove shackle 3 2 Take the key out Slide out core 8 making sure to carefully set aside the spring loaded parts 4 5 6 7 12 13 Removable Shackle Disassembly Instructions ...

Page 17: ...ic catch can be mounted NOTE Do not pull the cylinder out of the core more than two thirds of the way Mount the plastic catch and remove the cylinder 4 Insert the key into the cylinder and turn it until the pins can be removed from the plug C A B 3 4 Removable Shackle Disassembly Instructions ...

Page 18: ...Open Shackles 10 13 16 No Part No Part No Part 1 Key 6 Thrust plate 11 Plug 2 Shell 7 Short latch 12 Hive 3 Shackle spring 8 Latch spring 13 Dust shutter 4 Shackle 9 Core 14 Spring 5 Long latch 10 Threaded pin 10 32 UNF 15 Hardened pin Pop Open Shackles 10 13 16 ...

Page 19: ...Unlock the padlock with the operating key Using a 2 5 mm allen key remove the threaded pin 10 Remove shackle 4 and spring 3 2 Take the key out Slide out core 9 making sure to carefully set aside the spring loaded parts 5 6 7 8 13 14 15 Pop Open Shackle Disassembly Instructions 2 ...

Page 20: ... the plastic catch can be mounted NOTE Do not pull the cylinder out of the core more than two thirds of the way Mount the plastic catch and remove the cylinder 4 Insert the key into the cylinder and turn it until the pins can be removed from the plug Pop Open Shackle Disassembly Instructions ...

Page 21: ... hardened pin 15P and spring 3P 2 To convert a pop open shackle lock into a removable shackle lock change threaded pin 10P to set screw 9R Replace pop open shackle 4P with a removable shackle 3R Remove hardened pin 15P and spring 3P NOTE R removable shackle part P pop open shackle part For assembly refer to Assembly Instructions and Exploded Views pages for types P and R 4P 10P 3R 15P 9R 3P Conver...

Page 22: ...1 5 No Part No Part No Part 1 Key 6 Thrust Plate 11 Plug 2 Shell 7 Short latch 12 C8 Hive 3 Shackle Spring 8 Latch Springs 13 Shutter 4 Shackle 9 Core 14 Shutter Spring 5 Long latch 10 Threaded pin 10 32 UNF Pop Open Shackle No 8 Pop Open Shackle No 8 ...

Page 23: ...rating key Using a 2 5 mm allen key remove the threaded pin 10 Remove shackle 4 and spring 3 4 2 10 3 9 14 13 15 6 7 8 5 2 Take key out Slide out core 9 making sure to carefully set aside the spring loaded parts 5 6 7 8 13 14 15 1 2 Pop Open Shackle No 8 Disassembly Instructions ...

Page 24: ...h can be mounted NOTE Do not pull the cylinder out of the core more than two thirds of the way Mount the plastic catch and remove the cylinder C B A 3 4 4 Insert the key into the cylinder and turn it until the pins can be removed from the plug Cylinder Service Pop Open Shackle No 8 Cylinder Service ...

Page 25: ... 12 11 5 14 15 16 Single Pin No Part No Part No Part 1 Key 7 Thrust plate 13 Plug 2 Shell 8 Long latch 14 Shutter 3 Locking pin 9 Latch spring 15 Shutter spring 4 O Ring 10 Core 16 Hive 5 Pin 11 Set screw M5 6 Short latch 12 Lower pin Single Pin ...

Page 26: ...nlock the padlock with the operating key Using a 2 5mm allen key remove the set screw 11 Remove locking pin 3 2 Take key out Slide out core 10 making sure to carefully set aside the spring loaded parts 6 7 8 15 16 Remove pins 4 5 12 2 11 3 2 Single Pin Disassembly Instructions ...

Page 27: ...hat the plastic catch can be mounted NOTE Do not pull the cylinder out of the core more than two thirds of the way Mount the plastic catch and remove the cylinder 4 Insert the key into the cylinder and turn it until the pins can be removed from the plug Single Pin Disassembly Instructions ...

Page 28: ... Bolt Part No Part No Part No Steel pin 15 Bolt 8 Rear protecting plate 1 Set screw M4x4 16 Plug 9 Shell 2 Grooved pin 17 Dust shutter 10 Spring 3 Spring 18 Front protecting plate 11 Bolt pusher 4 Spring 19 Spring 12 Core 5 Latch 20 Hive 13 Stopper 6 Adaptor 14 Spring 7 SBC 13 Sliding Bolt ...

Page 29: ...2 1 Unlock the padlock with the operating key Mount the disassembling ring onto the bolt as illustrated 1A Remove the bolt 8 by pulling it out 2 Remove pin 6 and spring 7 Push grooved pin 17 up while sliding core out SBC 13 Sliding Bolt Disassembly Instructions ...

Page 30: ... force on spring 18 insert screwdriver and push inside bolt pusher 4 Key will return to closed position and can be taken out 1 3 4 15 12 11 16 15 15 16 10 4 4 Remove three pins 15 and two screws 16 Remove parts 1 3 4 10 11 12 18 17 19 3 SBC 13 Sliding Bolt Disassembly Instructions ...

Page 31: ...e mounted NOTE Do not pull the cylinder out of the core more than two thirds of the way Mount the plastic catch and remove the cylinder 6 Insert the key into the cylinder and turn it until the pins can be removed from the plug Assembly tip Latch 20 goes inside before adaptor 14 SBC 13 Sliding Bolt Disassembly Instructions ...

Page 32: ...1 10 9 4 5 7 G Series Padlock Padlock G 47 No Part No Part No Part 1 Key 5 Latch 9 Shackle 2 Cylinder 6 G 47 body 10 Ball bearing 8 mm 3 Cam limiter 7 Security pin 4 Cam activator 8 Screw M4x10 Elongated ball bearing Padlock G 47 ...

Page 33: ...8 6 3 2 10 9 4 5 7 1 Padlock G 47P No Part No Part No Part 1 Key 5 Latch 9 Shackle 2 Cylinder 6 G 47 body 10 Ball bearing 8 mm 3 Cam limiter 7 Security pin 4 Cam activator 8 Screw M4x10 Elongated ball bearing Padlock G 47P ...

Page 34: ...ies Padlock 8 6 3 2 1 5 9 4 5 7 Padlock G 55 No Part No Part No Part 1 Key 4 Cam activator 7 Security pin 2 Cylinder 5 Latch 8 Screw M4x10 3 Cam limiter 6 G 55 body 9 Shackle Elongated ball bearing Padlock G 55 ...

Page 35: ...es Padlock 8 6 3 2 1 5 9 4 5 7 Padlock G 55P Padlock G 55P No Part No Part No Part 1 Key 4 Cam activator 7 Security pin 2 Cylinder 5 Latch 8 Screw M4x10 3 Cam limiter 6 G 55 body 9 Shackle Elongated ball bearing ...

Page 36: ...ies Padlock 8 6 3 2 1 5 9 4 5 7 Padlock G 60 Padlock G 60 No Part No Part No Part 1 Key 4 Cam activator 7 Security pin 2 Cylinder 5 Latch 8 Screw M4x10 3 Cam limiter 6 G 60 body 9 Shackle Elongated ball bearing ...

Page 37: ...ge for instructions on removing the security pin 1 With the shackle 9 inside hold the padlock body 6 upside down Push the two elongated ball bearings 5 for G 55 padlocks 5 10 for G 47 padlocks through the cylinder opening one per side NOTE For G 47 models ensure that the elongated ball bearing 5 is placed in the direction of the short leg of the shackle 2A 2 Insert the padlock activator via the cy...

Page 38: ...der 2 into its place making sure that the key will be at it s removal point when the padlock is locked 4 Put the cylinder holding screw 8 into its place In order to prevent it from working loose secure it with a drop of LOCTITE For additional safety use the security pin 7 as described on the next page G Series Padlock Assembly Instructions ...

Page 39: ...ecurity pin 2 Once the screw is out use a punch and drive in the pin which will fall into the cavity above the cylinder The cylinder can now be removed and you can recover the pin for re assembly 3 Assemble the cylinder in position with the mounting screw and tighten Check the lock for correct operation Once confirmed drive the security pin home with a small hammer The pin end should be flush with...

Page 40: ...ing Bolt SBG No Part No Part No Part 1 Key 5 Ball bearing 8 mm 9 Bolt retaining pin 2 Cylinder 6 Locking bolt pin 10 Socket screw M5 3 Cam limiter 7 Sliding bolt 11 Lock body 4 Activator cam 8 Bolt retaining pin Spring 1 2 3 4 8 9 10 11 6 5 7 ...

Page 41: ... 1 Mount on the bolt 7 disassembling ring and remove the bolt by pulling it out 2 Take out pin and spring 8 9 Take out the key 1 3 Using 2 5 mm allen key insert into hole and loosen the screw 10 Now the cylinder is free via opening in side remove cylinder and inner parts of the body Disassembling of the locking mechanism is not needed for re keying 8 9 2 10 ...

Page 42: ...rly before inserting the bolt 4 5 Sliding Bolt SBG Disassembly Assembly Instructions 4 Via the opening in side remove inner parts of the body 3 4 5 6 NOTE Disassembling the locking mechanism is not needed for re keying 5 After re keying the cylinder insert all the inner parts and fasten the screw 3 4 5 6 3 4 6 5 ...

Page 43: ...41 G Series Padlock 6 5 4 3 2 7 1 Round Padlock Hockey Puck Type No Part No Part No Part 1 Key 4 Connecting Pin 7 Screw 2 Cylinder 5 Bolt 3 Cylinder Base 6 Padlock Body Round Padlock Hockey Puck Type ...

Page 44: ...NOTES ...

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Page 48: ...oor opening solutions dedicated to satisfying end user needs for security safety and convenience The Mul T lock name and Muscleman Logo and any other name mark or logo used by Mul T Lock and marked by an or sign are registered pending trademarks of Mul T Lock Ltd in various countries Mul T Lock reserves the right to make any product improvements or modifications without prior notice Mul T Lock Tec...