I finished. Here is a complete Abloy Disck Lock breakdown:
Tools Needed:
Abloy Disk Padlock with key
5/64" Allen Wrench
Tweezers
Recommended:Table with raised edges to keep parts from rolling off and traveling to the land of missing socks
Procedure:
Here's what I started with. I decided to use the tweezers later as the disks are a PAIN to reload.
The First thing you need to do is open the lock, like so:
With the padlock open, on one side you can see a hole. Within this hole is an allen (slug) screw. Unscrew this with the 5/64" allen wrench. Don't worry about anything at this point, nothing will pop out or do anything unexpected. You could even use the lock at this point. There's just nothing from keeping someone from removing the disk pack.
It was kinda wierd getting at the allen (grub) screw, so here's a pic to give you guys an view of the angle:
Now you need to remove the screw which holds all the disks in. I used the back end of a Brinks padlock key (nasty little bugger with spools, but that's beside the point). It (Screw, not key) unscrews just like any, not a reverse thread.
With that screw out, you need to watch what you do. Keep the padlock upside down, or you'll have quite a mess.
I put the key in, and attempted to slide all the disks out. This works OK, but you still need to be very cautious.
With the disk pack out, you can see the sidebar and the tops of all the disks. That brass disk looks to be a washer in between screw which holds all the disk in and the disks.
Once the disk pack is out, just pull out the shackle and tilt the padlock body around. The ball bearings will fall out.
Here is the disk pack with the sidebar in. It isn't all the way down, and is also spring loaded, as shown in later pictures.
Here's the disk pack with the sidebar removed, and key inserted (NOT turned). Notice different depths in disks.
With the key rotated, they all align and make a nice little channel for the sidebar to fall into.
With all the disks out, there are 2 rods which sit in channels in the bottom. In the background, you can see the sidebar.
Here's the springs I talked about earlier. The sidebar spring is usually down further, but I pulled it up in order to show it. The other one sticks out like that and pushes the disk pack against the screw on the bottom of the lock.
Here's the fully disassembled lock. I may have moved some disks around to keep some of you less honest viewers from knowing my lock code, but be rest assured that they are still the way you need to know to see how they are arranged in the lock.
Here's some pics of the disks.
As for reassembly, it's just the reverse of disassembly. Just be careful to put the disks in the correct way. The disks were shown right-side up in the pictures above. There are some which have a shallow protrusion followed by an indent (see pics above). The protrusion points IN. It won't work the other way around. The balls are also a BEAR in putting back in. Put in the shackle, then just dump them in. At that point, use a pick or something to push them into their respective holes. Then put in the disk pack, the bottom screw, and finally the allen (grub) screw. You will have to open the lock in order to get at the allen screw, and it will be in the locked position when re-inserting the disk pack. Here's what it should look like when done.
I always like to have someone check my work, so I had quality control do it. He's had a long day already (Ducks keep on trying to use our covered pool as a private pond), so he's a bit tired. He took a minute to check my work, and it passed his inspection.
Questions?
If anyone wants some closeups on something, feel free to ask. This thing was really fun and different. I can understand why Han Fey likes them so much.
Mods- Make any changes you see fit.
It's been fun,
Brooks
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