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Mul-t-lock Padlock E Series Service Manual

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Summary of Contents for Mul-t-lock Padlock E Series

  • Page 1 Padlock Service Manual...

  • Page 3: Table Of Contents

    Table of Contents Series Padlock ................2 Protected shackle ................3 Disassembly Instructions ..............4 Assembly Instructions ...............6 Sliding Bolt (SBE) ................9 Disassembly Instructions ..............10 Assembly Instructions ..............12 Series Padlock .................13 Removable Shackles 10, 13 & 16 ..........13 Removable Shackle ................14 Disassembly Instructions ..............14 Pop-Open Shackles 10, 13 & 16 ..........16 Disassembly Instructions ..............17 Conversion between Removable Shackle and Pop-Open Shackle ..............19 Pop-Open Shackle No. 8 ...............20 Disassembly Instructions ..............21...

  • Page 4: Series Padlock

    Series Padlock Part Part Part Padlock body Locking plate Ball St. Steel Socket head Shackle Bumper screw Identification Activator cam Spring for shutter plate Body cover Unified shutter Cylinder...

  • Page 5: Protected Shackle

    Protected shackle Part Part Part Padlock body Locking plate Ball St. Steel Socket head Shackle Bumper screw Identification Activator cam Spring for shutter plate Body cover Unified shutter Cylinder Protected shackle...

  • Page 6: Disassembly Instructions

    Disassembly Instructions • Unlock the padlock with the operating key. • Unscrew one socket head screw (10) using 3 mm “allen” key. Remove locking plate (5). • Lock the padlock with the operating key. • Take operating key out and remove body cover (4).
  • Page 7 • Remove shutter spring (11) and shutter (8). • Remove cylinder (12), activator cam (3) and two ball bearings (9). • Remove shackle (2). Protected shackle / Disassembly Instructions...

  • Page 8: Assembly Instructions

    Assembly Instructions • Insert shackle (2) in the position as illustrated. • NOTE: Pay special attention to shackle position (height and rotation)! • Insert two ball bearings (9). • Insert activator cam (3) in shown position. • NOTE: Activator cam (3) is not symmetrical. See diagram 3-A.
  • Page 9 • Insert cylinder (12). • Insert operating key and rotate the cylinder until it reaches the right position. • Lock cylinder (12) and remove operating key. • Install shutter (8) and shutter spring (11). Protected shackle / Assembly Instructions...

  • Page 10: Body Cover

    • Install body cover (4). • Insert operating key and unlock shackle (2). • Install locking plate (5). Using 3 mm “allen” key tighten the socket head screw (10). Protected shackle / Assembly Instructions...

  • Page 11: Sliding Bolt (Sbe)

    Sliding Bolt (SBE) Part Part Part Activator cam Cylinder front Ball bearing 5 mm Bolt pusher cover Ball bearing 4 mm Latch hole plug Plastic bumper Shutter spring Spring Bolt stopper Socket set screw Shutter Latch with cone point Spring for bolt Cylinder Lock body stopper...

  • Page 12: Disassembly Instructions

    Disassembly Instructions • Unlock the padlock with operating key. • Mount on the bolt disassembling ring and remove the bolt (21) by pulling it out. • Take out pin and spring (18,20). • Using screwdriver push the bolt pusher (16) until the latch (12) pops up.
  • Page 13 • Remove bumper (17). • Using 2.5 mm “allen” key insert into hole (located beneath bumper) and loosen screw (19) until until the cylinder cover can be removed (Do not disassemble completely). • Remove cylinder front cover (2), shutter spring (4) and shutter (5). •...

  • Page 14: Assembly Instructions

    Assembly Instructions • Install activator cam (8) and cylinder (6). • Install shutter spring (4) and shutter (5). • Place cylinder front cover (2) using 2.5 mm “allen” key, tighten screw (19). • Install pin and spring (18,20). Push them back with a screwdriver until the shackle is inserted.

  • Page 15: Series Padlock

    Series Padlock Removable Shackles 10, 13 & 16 Part Part Part Short latch Hive Shell Latch spring Dust shutter Dust shutter Shackle Core spring Long latch Set screw M5 Thrust plate Plug Removable Shackles 10, 13 & 16...

  • Page 16: Removable Shackle

    Removable Shackle Disassembly Instructions • Unlock the padlock with the operating key. • Using a 2.5 mm “allen” key, remove the set screw (9). • Remove shackle (3). • Take the key out. • Slide out core (8), making sure to carefully set aside the spring-loaded parts (4,5,6,7,12,13).
  • Page 17 • Turn the core upside down and pull out the cylinder so that 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.

  • Page 18: Pop-Open Shackles 10, 13 & 16

    Pop-Open Shackles 10, 13 & 16 Part Part Part Thrust plate Plug Shell Short latch Hive Shackle spring Latch spring Dust shutter Shackle Core Spring Threaded pin Long latch Hardened pin 10/32" UNF Pop-Open Shackles 10, 13 & 16...
  • Page 19 Disassembly Instructions • 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). • Take the key out. • Slide out core (9), making sure to carefully set aside the spring-loaded parts (5, 6, 7, 8, 13,...
  • Page 20 • Turn the core upside down and pull out the cylinder so that 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.

  • Page 21: Conversion Between Removable Shackle And Pop-Open Shackle

    Conversion between Removable Shackle and Pop-Open Shackle • To convert a removable shackle lock into a pop open shackle lock, change set screw (9R) to socket threaded pin (10P). • Replace removable shackle (3R) with pop-open shackle (4P). • Add hardened pin (15P) and spring (3P). •...

  • Page 22: Pop-Open Shackle No. 8

    Pop-Open Shackle No. 8 Part Part Part Thrust Plate Plug Shell Short latch C8 Hive Shackle Spring Latch Springs Shutter Shackle Core Shutter Spring Threaded pin Long latch 10/32" UNF Pop-Open Shackle No. 8...

  • Page 23: Disassembly Instructions

    Disassembly Instructions • 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). • Take key out. • Slide out core (9), making sure to carefully set aside the spring- loaded parts (5, 6, 7, 8, 13, 14, 15).

  • Page 24: Cylinder Service

    Cylinder Service • Turn the core upside down and pull out the cylinder so that 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.

  • Page 25: Single Pin

    Single Pin Part Part Part Thrust plate Plug Shell Long latch Shutter Locking pin Latch spring Shutter spring O - Ring Core Hive Set screw M5 Short latch Lower pin Single Pin...

  • Page 26: Disassembly Instructions

    Disassembly Instructions • Unlock the padlock with the operating key. • Using a 2.5mm “allen” key, remove the set screw (11). • Remove locking pin (3). • Take key out. • Slide out core (10), making sure to carefully set aside the spring-loaded parts (6,7,8,15,16).
  • Page 27 • Turn the core upside down and pull out the cylinder so that 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.
  • Page 28 SBC-13 Sliding Bolt Part Part Part Rear protecting Bolt Steel pin plate Shell Plug Set screw M4x4 Spring Dust shutter Grooved pin Front protecting Bolt pusher Spring plate Core Spring Spring Stopper Hive Latch Spring Adaptor SBC-13 Sliding Bolt...
  • Page 29 Disassembly Instructions • 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. • Remove pin (6) and spring (7). • Push grooved pin (17) up while sliding core out.

  • Page 30: Sbc-13 Sliding Bolt

    • Remove grooved pin (17) and spring (19). • To take key out, apply force on spring (18), insert screwdriver and push inside bolt pusher (4). • Key will return to closed position and can be taken out. • Remove three pins (15) and two screws (16).
  • Page 31 • Turn the core upside down and pull out the cylinder so that 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.

  • Page 32: Series Padlock

    Series Padlock Padlock G-47 Part Part Part Latch* Shackle Ball bearing Cylinder G-47 body 8 mm Cam limiter Security pin Cam activator Screw M4x10 * Elongated ball bearing Padlock G-47...

  • Page 33: Padlock G-47

    Padlock G-47P Part Part Part Latch* Shackle Ball bearing Cylinder G-47 body 8 mm Cam limiter Security pin Cam activator Screw M4x10 * Elongated ball bearing Padlock G-47P...
  • Page 34 Padlock G-55 Part Part Part Cam activator Security pin Cylinder Latch* Screw M4x10 Cam limiter G-55 body Shackle *Elongated ball bearing Padlock G-55...

  • Page 35: Padlock G-55

    Padlock G-55P Part Part Part Cam activator Security pin Cylinder Latch* Screw M4x10 Cam limiter G-55 body Shackle *Elongated ball bearing Padlock G-55P...

  • Page 36: Padlock G-60

    Padlock G-60 Part Part Part Cam activator Security pin Cylinder Latch* Screw M4x10 Cam limiter G-60 body Shackle *Elongated ball bearing Padlock G-60...

  • Page 37: G-Series Padlock

    G-Series Padlock Assembly Instructions These assembly instructions are intended to walk you through the assembly process, starting with the padlock disassembled. If you start dismantling an assembled lock, please refer to the next page for instructions on removing the security pin. • 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.
  • Page 38 • Insert the cam limiter (3), ensuring that it engages with the protrusion of the activator (4). • Insert the cylinder (2) into its place, making sure that the key will be at it’s removal point when the padlock is locked. •...

  • Page 39: Security Pin

    Security Pin Assembly Instructions • Unlock the padlock with the operating key. Reach for the cylinder mounting screw through the shackle hole with a Philips screwdriver, release and remove it. This will not release the cylinder, which is still held by the security pin.

  • Page 40: Sliding Bolt (Sbg)

    Sliding Bolt (SBG) Part Part Part Ball bearing Bolt retaining pin 8 mm Cylinder Locking bolt pin Socket screw M5 Cam limiter Sliding bolt Lock body Bolt retaining pin Activator cam Spring Sliding Bolt (SBG)

  • Page 41: Disassembly & Assembly Instructions

    Disassembly & Assembly Instructions • Unlock the padlock with the operating key (1). • Mount on the bolt (7) disassembling ring and remove the bolt by pulling it out. • Take out pin and spring (8,9). • Take out the key (1). •...
  • Page 42 • 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. • After re-keying the cylinder insert all the inner parts and fasten the screw (3, 4, 5, 6) •...

  • Page 43: Round Padlock

    Round Padlock Hockey Puck Type Part Part Part Connecting Pin Screw Cylinder Bolt Cylinder Base Padlock Body Round Padlock Hockey Puck Type...
  • Page 44 NOTES...
  • Page 48 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.

This manual is also suitable for:

G seriesPadlock c seriesPadlock g-55Padlock g-55pPadlock g-60

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