american lock 1105 Series User manual

2003
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The Locksmith's Lock ®
The Locksmith's Lock®

1. View of Generic Padlock
2. Disassembly/Reassembly of Series 1105, 1205, 1305,
5100, 5200, 5260, 5300, 5360, 5530, 5560, 5570
3. Generic Padlock In Open and Closed Position
4. View of Retainer
5. View of Series 700 Padlock
6. Disassembly/Reassembly of Series 700
7. View of Cylinder Detail PTC12/14
8. Rekeying PTC12/14 Cylinder - Option 1
9. Rekeying PTC12/14 Cylinder - Option 2
10. Key Spacing, Depth Information and Pin Dimensions
11. Restricted Keyways
12. View of Coverplates
13. View of Series 748 Padlock
14. Disassembly/Reassembly of Series 748
15. View of Cylinder Detail Series 2000 and 2010
16. Disassembly/Reassembly Series 2000 and 2010
17. View of Cylinder Detail Series 2500
18. Disassembly/Reassembly Series 2500
19. View of 780/790 Padlocks/Deadlock Retainer
20. Disassembly/Reassembly Series 780/790
Key-In-Knob
21. View of Multi-Cylinder KIK Series 3600, 3700, 3800 Padlocks
22. Disassembly/Reassembly of KIK Series 3600, 3700, 3800
23. Drivers for KIK Series 3600, 3700, 3800
24. Key Advantage® Rekeying Instructions
25. Retainers for KIK Series 3600, 3700, 3800
Interchangeable Core
27. View of IC Series 1405 Padlocks
28. Disassembly/Reassembly of IC Series 1405
29. View of IC Series 3105, 3200, 3260, 3560, 3570 Padlocks
30. Disassembly/Reassembly of IC Series 3105, 3200, 3260, 3560, 3570
31. View of IC Series 3900 Padlocks
32. Disassembly/Reassembly of IC Series 3900
Tubular
33. View of Tubular Series 7200, 7260, 7300 Padlocks
34. Disassembly/Reassembly of Tubular Series 7200, 7260, 7300
35. View of Tubular Cylinder Detail
36. View of CylinderAssembly with Driver for Tubular Series
37. Rekeying Instructions - Tubular Cylinder Series 7000,7260, 7300
38. 7-Pin Center Tubular Lock Data Series 7000 & 8000
39. View of Tubular Cam Lock Construction Series 8000
Blade Tumbler Padlocks
41 . View of Blade Tumbler Series H10
42. Disassembly/Reassembly Blade Tumbler Cylinder Series H10
43. View of Blade Tumbler Series L50
44. Disassembly/Reassembly of Blade Tumbler Series L50
45. Cylinder Detail - Series H10 & L50
Laminated Padlock
46. Rekeyable Laminated Padlock
Section Two - Service Parts PAGES 1-37
Table of Contents
Section One - Service Manual

Example 1
BYPASS PLATE
View of Generic American Lock Company Lock
USA
1
ANTI-

Example 2
View of Retainer for Removal
View 1
Retainer assembly
lock in locked
position
View 2
Retainer assembly
plus cylinder
View 3
Fully assembled
lock in locked
position
View 4
Fully assembled
lock in open
position
4
Bottom of Lock Body Assembly
RETAINER CYLINDER ASSEMBLY COVERPLATE LOCKED COLVERPLATE UNLOCKED

SERIES 1105, 1205, 1305, 5100, 5200, 5260, 5300, 5360, 5530, 5560, 5570
Using standard commercial retainer (non-key retaining feature)
DISASSEMBLY OF PADLOCK
1. Insert key and rotate clockwise to open shackle.
2. Remove the key.
3. Rotate shackle to expose shackle hole.
4. Using a #2 Phillips screwdriver, remove the security screw that is at the bottom of the
exposed shackle hole.
5. Remove the security nut and coverplate.
6. Remove cylinder assembly and by-pass restriction plate.
7. Using needle nose pliers, grip retainer as shown in example 2.
8. While holding onto the lockbody and shackle, remove retainer.
9. Remove the shackle and shackle spring.
10. Remove the two ball bearings.
REASSEMBLY OF PADLOCK
1. Insert shackle spring into shackle hole.
2. Insert shackle into shackle holes and hold in closed position.
3. Hold the lockbody with cylinder plug holes pointing upward and the shackle in the close
position. (Grasp body with hand and use table top to hold shackle.)
4. Insert the two ball bearings one at a time through the center plug hole and into the
ballnest hole. One ball toward each shackle leg so that each ball bearing is in the ball
pocket of each shackle leg. (A light grease may be needed to keep the ball bearings
from falling out of position.)
5. Insert retainer making sure that the retainer washer tab that is holding the spring is lined
up with the half round hole in the lockbody.
6. Push retainer down until it bottoms out in hole. (If the retainer assembly will not go to
the bottom of the hole, it may be necessary to turn the retainer clockwise while pushing
down on the retainer. This will line up the retainer pockets with the ball bearings and
allow the retainer to be pushed to the bottom of the hole.)
7. The shackle should now be in the closed position and held in place. Use the retainer
turning tool and open the shackle to check function.
8. Insert cylinder assembly with key removed and with by-pass restriction plate on end of
plug into the lockbody. Rotate cylinder clockwise until the bible of the cylinder stops it
from turning.
9. Insert coverplate and security nut.
10. While holding coverplate and security nut in position, check function of padlock by
opening lock with key and closing shackle. If padlock does not function properly, try to
identify the problem and correct, or disassemble and restart assembly again.
11. Open the padlock, rotate shackle to expose shackle hole, insert the security screw and
tighten into security nut.
Note:
When servicing a lock assembly with a dead lock retainer (key retaining feature), the shackle must be in the
closed position any time the key needs to be rotated and removed from the cylinder assembly.
Service Parts reference page 1-12
2

SERIES 700
Using standard commercial retainer (non-key retaining feature)
DISASSEMBLY OF PADLOCK
1. Insert key and rotate clockwise to open shackle.
2. Remove the key.
3. Rotate shackle to expose shackle hole.
4. Using a #2 Phillips screwdriver, remove the security screw that is at the bottom of the
exposed shackle hole.
5. Remove the security nut and coverplate.
6. Remove cylinder assembly and by-pass restriction plate.
7. Using needle nose pliers, grip retainer as shown in example 2.
8. While holding onto the lockbody and shackle, remove retainer.
9. Using a 1/8” Allen wrench, remove the dog point screw located on the back side of the
lockbody.
10. Remove the shackle and shackle spring.
11. Remove the two ball bearings.
REASSEMBLY OF PADLOCK
1. Insert shackle spring into shackle hole.
2. Insert shackle into shackle holes and hold in closed position.
3. Screw in and tighten dog point screw using 1/8” Allen wrench.
4. Hold the lockbody with cylinder plug holes pointing upward and the shackle in the
closed position. (Grasp body with hand and use table top to hold shackle.)
5. Insert the two ball bearings one at a time through the center plug hole and into the
ballnest hole. One ball toward each shackle leg so that each ball bearing is in the ball
pocket of each shackle leg. (A light grease may be needed to keep the ball bearings
from falling out of position.)
6. Insert retainer making sure that the retainer washer tab that is holding the spring is lined
up with the half round hole in the lockbody.
7. Push retainer down until it bottoms out in hole.
8. The shackle should now be in the closed position and held in place. Use the retainer
turning tool and open the shackle to check function.
9. Insert cylinder assembly with key removed and with by-pass restriction plate on end of
plug into the lockbody. Rotate cylinder clockwise until the bible of the cylinder stops it
from turning.
10. Insert coverplate and security nut.
11. While holding coverplate and security nut in position, check function of padlock by
opening lock with key and closing shackle. If padlock does not function properly, try to
identify the problem and correct, or disassemble and restart assembly again.
12. Open the padlock, rotate shackle to expose shackle hole, insert the security screw and
tighten into security nut.
Note:
When servicing a lock assembly with a dead lock retainer (key retaining feature), the shackle must be in the
closed position any time the key needs to be rotated and removed from the cylinder assembly.
Service Parts reference page 13 - 15
6

PTC 12/14 CYLINDER
REKEYING THE PTC 12/14 CYLINDER
(For Series 700, 748, 780, 790, 1105, 1205, 1305, 5100, 5200, 5260, 5300, 5360, 5530, 5560, 5570)
Option 1 (Remove and replace pins from bottom of cylinder assembly)
1. Remove cylinder from padlock.
2. Insert key and rotate key and plug 180 degrees (1/2 revolution).
3. Remove key and drop bottom pins through holes in the bottom of cylinder.
4. Turn cylinder over so that holes in cylinder are pointing up.
5. Insert new key and replace bottom pins through holes in cylinder, that match the new
key depths. The tapered end of the pins point toward the key.
(A #1 key cut gets a #1 bottom pin, a #2 key cut gets a #2 bottom pin, etc.)
6. Make sure that all pins are flush with top of plug.
7. When all pins are in place, return the key to neutral position by rotating key and plug
180 degrees (1/2 revolution) and withdraw key.
8. The cylinder is now ready to be reinstalled into padlock.
8

REKEYING THE PTC 12/14 CYLINDER
(For Series 700, 748, 780, 790, 1105, 1205, 1305, 5100, 5200, 5260, 5300, 5360. 5530, 5560, 5570)
Option 2 (Removal of plug from the cylinder assembly)
1. Remove cylinder from padlock.
2. Remove retaining ring from end of plug.
3. Insert key and rotate key and plug 45 degrees (1/8 revolution) counterclockwise.
4. Place the follower tool against the backside of the plug and slide the follower into the
cylinder while pushing plug out. (Be careful not to have a gap between the plug and
followers and allow the top pins and tumbler springs to fly out.)
5. Remove old bottom pins.
6. Insert new key and replace bottom pins that match new key depths. The tapered end of
the pins point toward the key. (A #1 key cut gets a #1 bottom pin, a #2 key cut gets a #2
bottom pin, etc.)
7. Make sure that all pins are flush with top plug.
8. Place plug against follower and slide plug into the cylinder at the same 45 degree angle
while pushing follower out. (Be careful not to have a gap between the plug and follower
and allow the top pins and tumbler springs to fly out.) This is a reverse of Step 4.
9. Replace retaining ring on end of plug.
10. Return key to neutral position and remove key.
11. The cylinder is now ready to be reinstalled into the padlock.
9

1 - .2840"
2 - .2684"
3 - .2528"
4 - .2372"
5 - .2215"
6 - .2059"
7 - .1903"
8 - .1747"
Depth
SPACING
(.156" first,
.125" inc.) (.093" / .094" Dia.)
A.L.C. 5 & 6 PIN TUMBLER KEY SPACING & DEPTH
10
Bottom Pins Master Pins Top Pins
1 - .1094" 2 - .0312" .1406"
2 - .1250" 3 - .0468"
3 - .1406" 4 - .0625"
4 - .1562" 5 - .0781"
5 - .1719" 6 - .0937
6 - .1875 7 - .1093
7 - .2031
8 - .2187
PIN DIMENSIONS

SERIES 748
Using standard commercial retainer (non-key retaining feature)
DISASSEMBLY OF PADLOCK
1. Insert key and rotate clockwise to open shackle.
2. Remove the key.
3. Rotate the shackle to expose the shackle hole.
4. Using a 5/32” Allen wrench, remove the security screw that is at the bottom of the exposed
shackle hole.
5. Remove the cylinder housing and slide the coverplate out using needle nose pliers.
6. Remove the cylinder assembly and by-pass restriction plate.
7. Using needle nose pliers, grip retainer as shown in example 2.
8. While holding onto lockbody and shackle, remove retainer.
9. Using a 1/8” Allen wrench, remove the dog point screw located on the back side of the lockbody.
10. Remove the shackle and shackle spring.
11. Remove the two ball bearings.
ASSEMBLY OF PADLOCK
1. Insert shackle spring into shackle hole.
2. Insert shackle into shackle holes and hold in closed position.
3. Screw in and tighten dog point screw using 1/8” Allen wrench.
4. Hold the lockbody with cylinder plug holes pointing upward and the shackle in the closed posi-
tion. (Grasp body with hand and use table top to hold shackle)
5. Insert the two ball bearings one at a time through the center plug hole and into the ballnest hole.
One ball toward each shackle leg so that each ball bearing is in the ball pocket of each shackle
leg. (A light grease may be needed to keep the ball bearings from falling out of position.)
6. Insert retainer making sure that the retainer washer tab that is holding the spring is lined up with
the half round hole in the lockbody.
7. Push retainer down until it bottoms out in hole.
8. The shackle should now be in the closed position and held in place. Use the retainer turning
tool and open the shackle to check function.
9. Insert cylinder assembly with key removed and with by-pass restriction plate on end of plug into
the lockbody. Rotate cylinder assembly clockwise until the bible of the cylinder stops it from
turning.
10. Insert coverplate into off centered plug hole and into slot in lockbody with needle nose pliers.
(Letter stamped on coverplate must face outward.)
11.Insert cylinder housing into off centered hole of lockbody.
12. Insert key partially into cylinder assembly and rotate until slot of cylinder housing engages the
bible of the cylinder causing the cylinder housing to bottom out.
13. While holding the cylinder housing in lockbody, check function of padlock by opening lock with
key. If padlock does not function properly try to identify the problem and correct, or disassemble
and restart assembly again.
14. Open the padlock, rotate shackle to expose shackle hole, insert the security screw and tighten
into the cylinder housing.
Note:
When servicing a lock assembly with a dead lock retainer (key retaining feature), the shackle must be in the
closed position any time the key needs to be rotated and removed from the cylinder assembly.
Service Parts reference page 16 - 18.
14