Masterlock ProSeries 6121, ProSeries 6121LN, ProSeries 6270, ProSeries 6121LJ, ProSeries 6121LF Technical Manual

...

TECHNICAL

MANUAL

ProSeries®Padlock

ISSUE 4.01

Master Lock introduced the ProSeries®product line in 1992 with Weather Tough®and High Security, iron shrouded, rekeyable padlocks. Intent on providing locksmiths with greater ease and flexibility, Master Lock designed the padlocks to use standard components across the line. Since then,

ProSeries

has grown to include solid body padlocks in Brass, Steel and Aluminum to further satisfy corrosion, security and safety requirements. Most recently, Master Lock has added extensive interchangeable core and door hardware cylinder options to create maximum options for padlock integration into facility padlock and door lock systems. Today,

ProSeries®is the only product line available for so many different

applications, making Master Lock the source for complete commercial security.

Table of Contents

ProSeries

Rekeyables Service Procedure 2

ProSeries

6230 Locks Service Procedure 3 ProSeries®6270 Lock Service Procedure 4 ProSeries

Rekeyables Component Parts 5-6 ProSeries®Interchangeable Core Service Procedure 7 ProSeries

Interchangeable Core Component Parts 8 ProSeries

Door Hardware Service Procedure 9 ProSeries®Door Hardware Component Parts 10 Cylinders and Retainers 11-13 Cylinder Service Procedure 14 Keys and Keyways 15 Keying 16 ProSeries

Extensions, Retainers and Drivers 17-18 Tools 19 Bitting Specifications 20 Terminology 21-29

All of the ProSeries®locks have a generic construction technology that allows for a uniform assembly and disassembly technique. Below is a stepby-step procedure for disassembling one of these padlocks (refer to diagram at right for parts and orientation). The only exceptions to this procedure will be the Door Hardware and IC versions of the lock.

• Use the key to unlock the shackle, A. (If the key is unavailable you will

have to use another method to unlock the shackle).

• Use a 7/64" hexagonal wrench to remove the mounting screw located

inside the toe side shackle hole.

• Holding the trap door, D, in place, lock the shackle, A, into the padlock

body. (This relieves pressure on the extension, E).

• Remove the trap door, D, and the nut, F.

• Remove the cylinder, C.

• Remove the extension, E.

• Remove the locking ball bearings, B, and shackle, A.

The order may be reversed to reassemble the lock. A light application of assembly grease may be used to hold the ball bearings in place during assembly.

If the lock only needs to be rekeyed, it is not necessary to remove the extension, ball bearings, or shackle.

Two functions are available in the locks, NKR (Non Key Retaining) and NRK (Non Removable Key) and both functions are accomplished as a design feature of the extension.

The NKR, non key retaining, function extension used in the lock has a projection on one side. You should note the orientation of this projection when removing the extension so that you can easily reinstall it during the reassembly process. Extensions are supplied with different sizes and two different styles have been used in the ProSeries

locks. Consult the

Extension section, page 17, of this manual for more detailed information.

The NRK, non removable key, function extension does not have a projection to help with orientation and you will have to rely on the position of the half-moon shaped actuator the tail of the cylinder contacts. Again, different sizes and styles are available for use in the ProSeries

locks, so consult the Extension section, page 17, of this manual for more detailed information.

See component parts list on page 5.

ProSeries®Rekeyables Service Procedure

The 6230 is a solid steel body lock using the ProSeries®standard ball bearing locking mechanism. Disassembling for servicing is similar to the rekeyables and may be accomplished by following the steps listed below (refer to diagram at right for parts and orientation).

• Use the key to unlock the shackle, A. (If the key is unavailable you will

have to use another method to unlock the shackle).

• Use a 7/64" hexagonal wrench to remove the mounting screw located

inside the toe side shackle hole.

• Holding the trap door, D, in place, lock the shackle, A, into the padlock

body. (This relieves pressure on the extension.)

• Remove the trap door, D, and the nut, F.

• Remove the cylinder, C.

• Remove the extension, E.

• Remove the locking ball bearings, B, and shackle, A.

The order may be reversed to reassemble the lock. A light application of assembly grease may be used to hold the ball bearings in place during assembly.

If the lock only needs to be rekeyed, it is not necessary to remove the extension, ball bearings, or shackle.

Two functions are available in the locks, NKR (Non Key Retaining) and NRK (Non Removable Key) and both functions are accomplished as a design feature of the extension.

The NRK, non removable key, function extension does not have a projection to help with orientation and you will have to rely on the position of the half-moon shaped actuator that the tail of the cylinder contacts.

See component parts list on page 6.

ProSeries®6230 Locks Service Procedure

The 6270 is a solid steel body lock. Disassembling for servicing is unique for this version and may be accomplished by following the steps listed below (refer to the diagram at the right for parts and orientation).

• Loosen or remove the cylinder mounting screw on the back of the lock

body with a 3/32" socket wrench.

• Use the key to unlock the shackle. (If key is unavailable you will have to

use another method to unlock the shackle).

• Pull on the cylinder to remove it.

• For rekeying, loosen the set screw, (1.5 mm), inside the last pin chamber

to allow 180° rotation of the plug.

• Align pin chambers in plug with service holes in the bottom of the shell

to remove existing bottom pins and replace with new combination.

• Rotate plug to key pull position and tighten the set screw in the last pin

chamber.

• To exchange the cylinder, remove the roll pin at the back of the plug,

remove the shackle and install shackle on a new cylinder.

The order may be reversed to reassemble the lock.

This lock is available with the ProSeries

K6000 or K7000 key. The 700A keyway is available for keying alike to other brands of locks which may be found in the field.

See component parts list on page 6.

ProSeries®6270 Locks Service Procedure

Vertical

Components

Model # Shackle Shackle Ball Bearings Cylinder Trap Door Extension Flared Nut Screw

Clearance (b) NKR NRK

ABCD E FG

2-1/8" Wide Laminated Steel Body. Shackle Dimensions: a: 5/16" c: 7/8"

6121 1-1/8" 293S6121

6121LF 1-1/2" 293LF6121 See List

6121LJ 2-3/8" 293LJS6121

6121-0427

Page 14

6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

6121LN 5-3/4" 293LNS6121

2-3/8" Wide Laminated Steel Body. Shackle Dimensions: a: 3/8" c: 7/8"

6125 1-3/8" 293S6125

6125LJ 2-3/8" 293LJS6125

6121-0427 See List, P. 14 6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

2-5/8" Wide Laminated Steel Body. Shackle Dimensions: a: 7/16" c: 7/8"

6127 1-3/8" 293S6127 6127LH 1-7/8" 293LHS6127 See List 6127LJ 2-3/8" 293LJS6127

6121-0427

Page 14

6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

6127LN 5-3/4" 293LNS6127

2-1/8" Wide Laminated Steel Body. Shackle Dimensions: a: 5/16" c: 7/8"

6321 3/4" 293S6321 6121-0427 See List, P. 14 6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

2-3/8" Wide Laminated Steel Body. Shackle Dimensions: a: 3/8" c: 7/8"

6325 3/4" 293S6325 6121-0427 See List, P. 14 6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

2-5/8" Wide Laminated Steel Body. Shackle Dimensions: a: 7/16" c: 7/8"

6327 3/4" 293S6327 6121-0427 See List, P. 14 6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

1-9/16" Wide Solid Brass Body. Shackle Dimensions: a: 1/4" c: 25/32"

6830 1-1/16" 293S6830

6830B 1-1/16" 293B6830 See List

6830LF 1-9/16" 293LFS6830

0220-0302

Page 14

6830-0420 6830-0421 6830-0422 6121-0421 6121-0422

6830LT 3" 293LTS6830

1-3/4" Wide Solid Brass Body. Shackle Dimensions: a: 5/16" c: 29/32"

6840 1-3/16" 293S6121

6840B 1-3/16" 293B6840 6840LF 1-9/16" 293LFS6121 See List 6840LJ 2-7/16" 293LJS6121

6121-0427

Page 14

6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

6840BLJ 2-7/16" 293LJB6840

6840LN 5-3/4" 293LNS6121

ProSeries®Rekeyables Component Parts

Weather Tough

Iron ShroudSolid Brass

d dd

ShroudedWeather Tough Brass/Aluminum/Steel

ProSeries®Rekeyables Component Parts

Vertical

Components

Model # Shackle Shackle Ball Bearings Cylinder Trap Door Extension Flared Nut Screw

Clearance (b) NKR NRK

ABCD E FG

2" Wide Solid Brass Body. Shackle Dimensions: a: 3/8" c: 29/32"

6850 1-1/2" 293S6125

6850B 1-1/2" 293B6850 See List

6850LJ 2-1/2" 293LJS6125

6121-0427

Page 14

6121-0420 6121-0423 6121-0424 6121-0421 6121-0422

6850BLJ 2-1/2" 293LJB6850

1-9/16" Wide High Visibility Aluminum Body. Shackle Dimensions: a: 1/4" c: 25/32"

6835RED 1-1/16" 293S6830

6835LFRED 1-9/16" 293LF6830

6835ORJ 1-1/16" 293S6830

6835LFORJ 1-9/16" 293LFS6830

6835YLW 1-1/16" 293S6830

6835LFYLW 1-9/16" 293LFS6830

0220-0302

See List

6830-0420 6831-0421 6830-0422 6121-0421 6121-0422

6835GRN 1-1/16" 293S6830 Page 14

6835LFGRN 1-9/16" 293LFS6830

6835BLU 1-1/16" 293S6830

6835LFBLU 1-9/16" 293LFS6830

6835BLK 1-1/16" 293S6830

6835LFBLK 1-9/16" 293LFS6830

1-9/16" Wide Solid Steel Body. Shackle Dimensions: a: 1/4" c: 25/32"

7030 1-1/16" 293S6830

See List

7030LF 1-9/16" 293LFS6830 0220-0302 6830-0420 6831-0421 6830-0422 6121-0421 6121-0422 7030LT 3" 293LTS6830

Page 14

1-3/4" Wide Solid Steel Body. Shackle Dimensions: a: 5/16" c: 29/32"

7040 1-3/16" 293S6121 See List

7040LJ 2-1/2" 293LJS6121

6121-0427

Page 14

6121-0420 6841-0421 6121-0424 6121-0421 6121-0422

2" Wide Solid Steel Body. Shackle Dimensions: a: 3/8 c: 29/32"

7050 1-1/2" 293S6125

6121-0427

See List

6121-0420 6841-0421 6121-0424 6121-0421 6121-0422

7050LJ 2-1/2" 293LJS6125 Page 14

2-1/2" Wide Round Solid Steel Body. Shackle Dimensions: A: 7/16" C: 7/8"

6230 1-1/8" 293S6230

230-0302

See List

6121-0420 6121-0425 6121-0426 6121-0421 6121-0422

6230LH 2 293LHS6230 Page 14

6270 N/A N/A N/A 6270-321 N/A N/A N/A N/A NA

1-9/16" Wide Solid Steel Body. Shackle Dimensions: a: 1/4" c: 25/32"

7035 1-1/16" 293S6830 See List, P. 14 6830-0420 6831-0421 6830-0422 6121-0421 6121-0422

1-3/4" Wide Solid Steel Body. Shackle Dimensions: a: 5/16" c: 29/32"

7045 1-3/16" 293S6121 Page 14 6121-0420 6841-0421 6121-0424 6121-0421 6121-0422

Solid AluminumSolid Steel

Shrouded

Solid Steel

Solid Brass

*Note: the 296W6000 cylinder is pinned with only 5 pins, for 6 pins order 296W7000

b b

d d

ShroudedWeather Tough Round SteelBrass/Aluminum/Steel Shrouded Solid Steel

The ProSeries®Interchangeable Core locks employ a construction technology similar to that used in the Rekeyables. It also allows for a uniform assembly and disassembly technique. Below is the step by step procedure for disassembling this version of padlock (refer to diagram at right for parts and orientation). The only exceptions to this procedure will be the Rekeyables and Door Hardware versions of the lock.

• Use the control key to remove the IC cylinder, C. (If key is unavailable you will have to use another method).

• Remove the ring retainer.

• Remove the steel retainer plate.

• Remove the throw member.

• Remove the extension, E.

• Remove the locking ball bearings, B, and shackle, A.

The order may be reversed to reassemble the lock. A light application of assembly grease may be used to hold the ball bearings in place during assembly.

If the lock only needs to be rekeyed, it is not necessary to remove the ring retainer, retainer plate, extension, ball bearings, or shackle.

Two functions are available in the locks, NKR (Non Key Retaining) and NRK (Non Removable Key) and both functions are accomplished as a design feature of the extension.

The NKR, non key retaining, function extension used in the lock has a projection on one side. You should note the orientation of this projection when removing the extension so that you can easily reinstall it during the reassembly process. Extensions are supplied with different sizes and orientations, and two different styles have been used in the ProSeries

locks. Consult the Extension section, page 17, of this manual for more detailed information.

locks, so consult the Extension section, page 17, of this manual for more detailed information.

See component parts list on page 8.

ProSeries®Interchangeable Core Service Procedure

ProSeries®Interchangeable Core Component Parts

Weather Tough

Iron

Shroud

Solid BrassSolid AluminumSolid Steel

Shrouded

Solid Steel

b b

d d

Shrouded Round SteelBrass/Aluminum/Steel Shrouded Solid Steel

Vertical

Components

Model # Shackle Shackle Ball Bearings Cylinder Trap Door Extension Flared Nut Screw

Clearance (b) NKR NRK

ABCD E FG

2-1/8" Wide Laminated Steel Body. Shackle Dimensions: a: 5/16" c: 7/8"

6421 1-1/8" 293S6121

6421LF 1-1/2" 293LF6121

6121-0427 See List P.13 N/A 6121-0423 6121-0424 N/A N/A

6421LJ 2-3/8" 293LJS6121 6421LN 5-3/4" 293LN6121

2-5/8" Wide Laminated Steel Body. Shackle Dimensions: a: 7/16" c: 7/8"

6427 1-3/8" 293S6127 6427LH 1-7/8" 293LHS6127 6427LJ 2-3/8" 293LJ6127

6121-0427 See List P.13 N/A 6121-0423 6121-0424 N/A N/A

6427LN 5-3/4" 293LN6127

2-1/8" Wide Laminated Steel Body. Shackle Dimensions: a: 5/16" c: 7/8"

6521 3/4" 293S6321 6121-0427 See List P.13 N/A 6121-0423 6121-0424 N/A N/A

2-5/8" Wide Laminated Steel Body. Shackle Dimensions: a: 7/16" c: 7/8"

6527 3/4" 293S6327 6121-0427 See List P.13 N/A 6121-0423 6121-0424 N/A N/A

1-9/16" Wide Solid Brass Body. Shackle Dimensions: a: 1/4" c: 25/32"

6831 1-1/16" 293S6830

6831B 1-1/16" 293B6830

0220-0302 See List P.13 N/A 6830-0421 6830-0422 N/A N/A

6831LF 1-9/16" 293LFS6830

6831BLF 1-9/16" 293LFB6830

1-3/4" Wide Solid Brass Body. Shackle Dimensions: a: 5/16" c: 29/32"

6841 1-3/16" 293S6121

6841B 1-3/16" 293B6840 6841LF 1-1/2" 293LFS6121 6121-0427 See List P.13 N/A 6841-0421 6121-0424 N/A N/A 6841LJ 2-7/16" 293LJS6121

6841BLJ 2-7/16" 293LJB6840

2" Wide Solid Brass Body. Shackle Dimensions: a: 3/8" c: 29/32"

6851 1-1/2" 293S6125

6851B 1-1/2" 293B6850

6121-0427 See List P.13 N/A 6841-0421 6121-0424 N/A N/A

6851LJ 2-1/2" 293LJ6125

6851BLJ 2-1/2" 293LJB6850

1-9/16" Wide High Visibility Aluminum Body. Shackle Dimensions: a: 1/4" c: 25/32"

6836RED 1-1/16" 293S6830 6836LFRED 1-9/16" 293LFS6830 6836LTRED 3" 293LTS6830

6836ORJ 1-1/16" 293S6830 6836LFORJ 1-9/16" 293LFS6830 6836LTORJ 3" 293LTS6830

6836YLW 1-1/16" 293S6830 6836LFYLW 1-9/16" 293LFS6830 6836LTYLW 3" 293LTS6830

0220-0302 See List P.13 N/A 6831-0421 6830-0422 N/A N/A

6836GRN 1-1/16" 293S6830 6836LFGRN 1-9/16" 293LFS6830 6836LTGRN 3" 293LTS6830

6836BLU 1-1/16" 293S6830 6836LFBLU 1-9/16" 293LFS6830 6836LTBLU 3" 293LTS6830

6836BLK 1-1/16" 293S6830 6836LFBLK 1-9/16" 293LFS6830 6836LTBLK 3" 293LTS6830

1-9/16" Wide Solid Steel Body. Shackle Dimensions: a: 1/4" c: 25/32"

7031 1-1/16" 293S6830 7031LF 1-9/16" 293LFS6830 0220-0302 See List P.13 N/A 6831-0421 6830-0422 N/A N/A 7031LT 3" 293LTS6830

1-3/4" Wide Solid Steel Body. Shackle Dimensions: a: 5/16" c: 29/32"

7041 1-3/16" 293S6121 7041LJ 2-1/2" 293LJS6121

6121-0427 See List P.13 N/A 6841-0421 6121-0424 N/A N/A

2" Wide Solid Steel Body. Shackle Dimensions: a: 3/8" c: 29/32"

7051 1-1/2" 293S6125

6121-0427 See List P.13 N/A 6841-0421 6121-0424 N/A N/A

7051LJ 2-1/2" 293LJS6125

1-9/16" Wide Solid Steel Body. Shackle Dimensions: a: 1/4" c: 25/32"

7036 1-1/16" 293S6830 0220-0302 See List P. 13 N/A 6831-0421 6830-0422 N/A N/A

1-3/4" Wide Solid Steel Body. Shackle Dimensions: a: 5/16" c: 29/32"

7046 1-3/16" 293S6121 6121-0427 See List P. 13 N/A 6841-0421 6121-0424 N/A N/A

+ 21 hidden pages

Masterlock ProSeries 6121, ProSeries 6121LN, ProSeries 6270, ProSeries 6121LJ, ProSeries 6121LF Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual