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Abloy PL231 questions

Information about locks themselves. Questions, tips and lock diagram information should be posted here.

Abloy PL231 questions

Postby bprzybyl » 5 Apr 2006 20:21

Hello all!
I FINALLY received the abloy padlock I purchased in the mail. HOORAY!!! Sorry, but I've been waiting for over a week for not only this, but some new picks as well. The picks at least should have arrived monday, considering the factory is literally a half hour drive from me. Needless to say, I was started to believe the postman was withholding them from me. But both arrived today...back on topic time.

This thing is sweet. The shackle isn't spring loaded, so I wasn't sure I turned the key enough when I tried to open it. The thing works great! Which brings me to question 1-

How can I tell wether or not it has 13 or 14 disks?

If you look on page 5 of Han Fey's Abloy article part 4 (http://www.toool.nl/abloypart4.pdf) He shows a cutaway of a PL231 with 13 and 14 disks. How can I find out which it is? My guess is my next question will answer that question-

How do I rip this bad boy apart?

There's a screwhole on the side, which has a set screw (slug scew for UK) inside it. Observing the cutaway as stated above, that screw keeps a screw in the bottom from coming undone. If I take out the set screw and then the screw keeping all the disks in out, what will happen? Will they all just fall out? Will they come out in that cylinder type thing that's shown holding all the disks in in the cutaways? Will I be transported to an alternate universe with no TV's without remotes and green skies?

Any help would be greatly appreciated,
Brooks
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Postby n2oah » 5 Apr 2006 20:27

First of all, you can count the cuts in the key to find out how many disks it has. There is usually one disk in the front that is not cut into the key. To take this lock apart (at least I think, I am going off of one of my abloys that is not the exact same model) pop up the shackle and use the appropriate tool to remove the grub screw. Then, you may unscrew the faceplate. Do this while holding it up so the disk pack doesn't dump out. Then, you can look inside and see the disk pack. Pull it out lightly and make sure everything comes with.
"Lockpicking is what robbing is all about!" says Jim King.
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Postby bprzybyl » 5 Apr 2006 21:14

Thanks n2oah!

Now I have a bunch of stuff sitting on a table. anyone got some help for reassembly?

I'll make a pic or how to once I figure all this out
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haHA!

Postby bprzybyl » 5 Apr 2006 21:48

I fixed it...well, returned it back to working before. I guess it's not really fixing if it wasn't broken.

I will take pictures of everything and post them here. SHOOT. I forgot to count the disks. There were 20 or so of them, but a bunch were just there to keep the fence/sidebar straight on top of the disks. Pictures will ensue. Dynamics can wait. The test isn't until friday anyway 8) .
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Postby bprzybyl » 5 Apr 2006 21:52

To any mods-
Should I post the pics in a new post with something like- "Abloy Disk Padlock Breakdown"?
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Postby n2oah » 5 Apr 2006 22:11

The other "disks" aren't actually considered disks, as they are stationary. They are actually called "washers" :wink:
"Lockpicking is what robbing is all about!" says Jim King.
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Finally

Postby bprzybyl » 6 Apr 2006 1:03

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.
Image

The First thing you need to do is open the lock, like so:
Image

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.
Image

It was kinda wierd getting at the allen (grub) screw, so here's a pic to give you guys an view of the angle:
Image

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.
Image

With that screw out, you need to watch what you do. Keep the padlock upside down, or you'll have quite a mess.
Image

I put the key in, and attempted to slide all the disks out. This works OK, but you still need to be very cautious.
Image

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.
Image

Once the disk pack is out, just pull out the shackle and tilt the padlock body around. The ball bearings will fall out.
Image

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.
Image

Here's the disk pack with the sidebar removed, and key inserted (NOT turned). Notice different depths in disks.
Image

With the key rotated, they all align and make a nice little channel for the sidebar to fall into.
Image

With all the disks out, there are 2 rods which sit in channels in the bottom. In the background, you can see the sidebar.
Image

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.
Image

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.
Image

Here's some pics of the disks.
Image
Image
Image
Image
Image

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.
Image

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.
Image

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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Postby skold » 6 Apr 2006 6:13

Even though my days consist of building these i still seem to find them interesting.

You should buy a cutaway next.
Image
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Postby n2oah » 6 Apr 2006 8:16

Nice breakdown photos. Remember to keep all of the washers in order, since the black washers are a little bit thicker than the normal (brass) coloured washers.
"Lockpicking is what robbing is all about!" says Jim King.
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noo

Postby bprzybyl » 6 Apr 2006 19:14

I'd be willing to bet that they (black ones) were thinner than all. If someone wants to challenge that, I'll whip out the caliper right now.
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Postby n2oah » 6 Apr 2006 19:40

Ah, you have me there. All I remembered is that there is a difference between the two. I pulled up the Abloy Part 2 article on TOOOL, and it says the copper washers are .59mm thick, and the black are .49mm thick. :wink:
"Lockpicking is what robbing is all about!" says Jim King.
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Postby bprzybyl » 6 Apr 2006 19:57

I knew it! I wasn't sure how by how much, but I was pretty sure that one was pretty sure that the black ones were. I gotta download all of those, I've viewed them all at least 3 times each. Regardless, this things cooler than all that and a bag of chips. I think I only have 9 disks, which makes sense according to Abloy Part 2. I have the Disklock Pro. I'm gonna try to remember to give my lockie a call tomorrow to get an extra key or 2 made. He's only open from 9-5, and I've got school until 6 most days. I am also forgetfull.

Thanks all,
Brooks
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Postby n2oah » 6 Apr 2006 20:27

No, I think you have the 11 disk model.
"Lockpicking is what robbing is all about!" says Jim King.
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Postby digital_blue » 6 Apr 2006 23:21

Those are some mighty nice pics!
Image
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Postby bprzybyl » 11 Apr 2006 0:09

I'm back! Not that I was ever gone, just had too much work to do.

Anyhow, I ripped it apart just now, and there are 10 things that move inside of it, and then there's one disk that looks like it should move, but doesn't. So I would concur with you, n2oah, that I have the 11 disk model. I think that leaves the score at:
bprzybyl: 1-0-1
n2oah: 1-0-1

I'll see if I can find something else to argue about. On another note, can anyone speculate as to the price of a copy of a key for this guy? I called my lockie as I said I would in an earlier post, but he referred me to "Upstate Lock" but I have yet to call them, and I don't think they'd fancy being bothered at this time of night.

Thanks all,
Brooks

P.S. - Thanks db
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