PRO-KEY TECHNICAL MANUAL
Contents Page Terminology 4 Introduction to Master Keying 5 Rules for Master Keying 7 Patent Protection 8 BEN1303 Explained 9 Key Data 10 Marking 11 Calculation and Pinning 12 eneral Assembly Procedure 13 Trouble hooting 14 Coding 15 Pro-Key ide-pin 17 ide-pin Coding/How to order 18 Cylinder Assembly ection 21 Component List Euro Profile 21 Assembly Instructions Euro Profile 22 Component List Oval Profile 24 Assembly Instructions Oval Profile 24 Component List Rim 25 Assembly Instructions Rim 26 Component List candinavian Oval 28 Assembly Instructions candinavian Oval 28 Component List crew In 29 Assembly Instructions crew In 30 Component List Camlock 31 Assembly Instructions Camlock 32 Component List Padlock/Knobset Cylinder 33 Assembly Instructions Padlock/Knobset Cylinder 34 Component List 840/841/850/851 Padlock 35 Component List 870/871 Padlock 36 Component List Bronze Padlocks 37 Assembly Instructions Bronze Padlocks 38 Lubrication Policy/Harsh Weather 41 Lead Times and Yale Contacts 42 Customer Documentation 43 Pro-Key ales Tools Online 44 Pro-Key ales Presenter 45
4 Terminology
Introduction A Pro-Key master key is a single key designed for your exclusive use. The system is fully patented and therefore the key cannot be reproduced by any person or persons who have not been legally authorised by Yale and yourself to do so. It will operate every Pro-Key cylinder which has been built to your unique Yale master key specification. But it will not operate any cylinder other than your own, neither will any other master key open the cylinders you use. Distribution of keys is controlled to ensure supply of blanks to a network of approved dealers only. Keys may only be cut by approved dealers and key cutting details are held jointly by Yale and the individual dealer with responsibility for each customer. Any order not bearing the correct authority will be reported to the suite holder (the individual responsible for the system). from factory floor to your door We do ask that any changes to authorised signatories are promptly notified to Yale to enable us to give continuing customer service. Having seen the security that Yale Pro-Key offers in your master key system, now consider the convenience of having one key instead of many. Imagine the weight this lifts from your pocket and mind. No matter what lock, latch or padlock has been specially adapted to this system be it in an office, factory, hospital, school or your home this Yale Pro-Key master key will open every lock you use, yet each lock can be different and have its own individual key. 5
Introduction Most Yale locks with pin tumbler cylinders are supplied individually keyed. To provide extra convenience and security, specially keyed systems have been developed to enable the customer to control those locks which an individual is authorised to operate. pecially keyed systems range from simple keyed-alike groups of locks operated by one key, to the more complex grand master keyed systems where many groups of locks are operated by one key. Principle of the pin tumbler cylinder A brief outline of the various systems is given here. Each system is specially designed to cover a number of important requirements such as security, convenience and rapid access to an area by night watchmen, fire brigade and other authorised personnel in the case of an emergency. Here are a few basic examples of how your Yale Pro-Key master key system can work for you but always remember that special needs for special people can be built into your unique system. imply contact us for professional advice and expertise. 6
Rules 1. Each Master Key bitting (from the list of 1000 supplied) can be used once ONLY. 2. uite references are used in sequential order starting with 1 upwards and never repeated. 3. The maximum number of steps between each key notch is 6 i.e. 151375 is okay but 151975 is not allowable 4. No more than 2 pins in a row can be alike i.e. 153322 is okay but 133322 is not allowable 5. No more than 3 pins can be alike in any master key or servant key bitting. 6. If the cylinders are used in a sensitive area ensure that all of the differ keys cannot be cut down to a master key. (afety Check Yes on Elcon) 7. A 10 cut can never be used in the first position (i.e. the cut nearest the bow). 8. Records must be updated monthly, to Yale ecurity Products Head Office. 7
Patent Protection Yale Pro-Key technology is protected by a 20 year patent. The patented feature of the system is the interactive 7th pin on both the key-bow and within the cylinder itself. The Pro-Key patent will expire on April 17th, 2017, giving many years of patent protection. The Pro-Key keyblank is currently protected by the following means: Patent protection rendering illegal any un-authorised duplication of keys Key registration key cutting and cylinder pinning details are held under strict security controls both by dealers (obliged by contractural terms to uphold key security) and the Yale UK factory Key design the interactive 7th pin adds a techical element to the key which prevents even illegal duplication 7th patented pin built into the key giving patented protection. 8
B EN 1303 Explained BEN1303 rade 5 (or CEN 5) is the highest European industry standard for security in cylinder locking. The tandard states the level of security required through several criteria, to achieve grades 1-5 within the standard. Yale Pro-Key cylinders have been designed and tested to exceed the requirements of CEN 5. The performance requirements of the standard are as follows: Resistance to 5 minutes drilling (3 x H 12mm drills) Resistance to 30 250mm twists Resistance to plug extraction (5 minutes of 15Kn of force, using a traction screw) Resistance to 30mm torque Minimum number of effective differs 100,000 Minimum number of movable detainers 6 Resistance to 96 hours corrosive salt spray exposure Cycle testing in action at Yale 9
Technical Key Data: The chart opposite shows cutting centres and cut angles. Keys must be cut to the above specification and cut within specified tolerances. Notch No. 1 2 3 4 5 6 7 8 9 10 Depth 8.35 7.95 7.55 7.15 6.75 6.35 5.95 5.55 5.15 4.75 10
Marking Cylinder Marking: Marking of key numbers on all cylinders must be done by the Dealer to allow traceability in the event of key loss. The opposite illustration shows the best places to position such marking on each cylinder type. Note: Care should be taken not to flatten the base of the cylinder All Profile Cylinders: Note: hould be marked on Thumbturn end. Padlock Inner Housing: Note: As in the case of all cylinders marking should not be excessively heavy on this face - you should make sure spring holes are not flattened. Care should be taken when clamping and hammering not to mark any finished surfaces. The suite reference should be as per the key marking. Key Marking: uite No. (generated from the list of 1000 suite numbers allocated to each dealer) Individual key reference number (if this is a change key, or a key for a differ cylinder) or key level (where the key is a control key and will be marked with the level, for example MK referring to rand Master-Key ) 11
Calculation and Pinning Opposite is a general guide to master-key calculation and pinning of Pro-Key cylinders. Always pin to the shallowest comparison between the individual differ key and the master key. Always insert drivers to the deepest comparison between the master key and the differ key. Examples: Pinning: E.g.-Master Key Differ Key Pinning required (hallowest comparison) 5 3 8 5 7 2 5 3 2 5 3 4 t t t t t t 5 3 2 5 3 2 Discing: E.g.- Master Key Differ Key Difference Disc ize 5 3 8 5 7 2 5 3 2 5 3 4 NONE NONE 8-2=6 NONE 7-3=4 4-2=2 NONE NONE 2 NONE 4 2 required Drivers (top pins): E.g.- Master Key Differ Key Driver Comparison Driver required 5 3 8 5 7 2 5 3 2 5 3 4 t t t t t t 5 3 8 5 7 4 t t t t t t 4.8(A) 4.8(A) 2.4(B) 4.8(A) 2.4(B) 4.8(A) For pin sizes 1-5, or an accumulative total (pin and master-key disc), use driver 4.8 (A). For pin sizes 6-10, or an accumulative total (pin and master-key disc), use driver 2.4 (B). For all euro-profile and scandinavian cylinders use a standard 6mm driver (top pin) only 12
Assembly 1. Insert the cylinder pins (there are 10 sizes available the smallest being (1) and the largest (10) in hole number sequence 1 to 6 (front of plug to back) Examine your pinning chart, read off the correct pin size and then insert the pin into the corresponding hole. ee example 1 2. Insert master key discs into the cylinder into the correct holes listed in your pinning chart. There are four sizes of master key disc. In example 1 we have inserted (see example 2) 3. The cylinder now has to be loaded with top-pins (drivers) and certain cylinder shapes require different toppins. Refer to component pages and to the inside lid of your pinning kit for details. Example 1: MK 737351 Key Differ 737513 Pin Numbers 737311 Plug Hole Numbers 123456 Into; Hole We Insert Pin ize No.1 7 No.2 3 No.3 7 No.4 3 No.5 1 No.6 1 Example 1: Hole No.4 No.5 No.6 Insert Disc No.2 No.4 No.2 4. Insert springs into the cylinder. 5. With the key inserted, insert the dummy stoppering tool to retain the components and test key operation. Both differ and control keys should be used when testing cylinder operation. 6. With operation satisfactorily tested, insert and rivet the stoppers using the stoppering punch and block. 7. Test key operation and lubricate using Tri-Flow 13
Maintenance Troubleshooting ymptom Cause Key doesn t turn Incorrect pins, coding or pin order Incorrect springs Incorrect key Incorrect cut key (incorrect code or tolerances) Damaged key Foreign matter or swarf tiff operation Incorrect lubrication (or mixing of lubricants) Foreign matter or swarf Incorrect pin/s inserted Incorrectly cut key (out of tolerance) 14
Coding Balancing Patented ecurity & Accessibility You can give Yale details of a new system or extension and we will either supply you with the coding required to build the system, or deliver the cylinders fully assembled. Pricing for calculation and assembly is detailed in the Yale Pro- Key dealer price list. When calculating your own system, dealers are required to update Yale by sending a monthly update disk for the attention of The Master Key Department. This enables all suite records to be backed-up by Yale, therefore ensuring that records are readily available in the event of a system crash, corrupt file etc. A specific record is only available to that particular dealer unless the end user requests that the records transfered to another dealer or back to Yale. Pro-Key strikes the right balance with patented protection and product flexibility. KEY CONTROLLER Authority to copy keys 4 Access to all areas 4 LEVEL 2 KEY HOLDER Authority to copy keys 7 Access to other defined rooms 4 LEVEL 1 KEY HOLDER Authority to copy keys 7 Access to high profile rooms 4 LEVEL 3 KEY HOLDER Authority to copy keys 7 Main entry/exit doors only 4 15
Coding Keys are cut from bow to tip with depths of 1 to 10 Calculations must be based on double-spacing between differs to prevent interpassing 90 degree included angle Maximum Adjacent Cut pecification (MAC) = 6. (1-7 is acceptable, 1-8 is not). Bottoms pins numbered 1-10 (1 = shortest pin, 10 = longest pin). Master key discs numbered 2, 4, 6, 8. (2 = shortest disc, 8 = longest disc). 16
Pro-Key ide Pin Pro-Key side pin (Phase 2) is the follow on from Pro-Key. The main benefits on moving forward to side pin are: It allows the network dealers to build much larger and complex suites. It does not alter any assembly method currently in use by the dealer. The dealer will receive the goods in sub assembled form as currently supplied. Cylinders How ide Pin Works On the cylinder plugs there are a series of holes drilled into each side of the plug. (ee illustration opposite) The plug will have 5 holes drilled along the right hand side and will give position numbers 1, 2, 3, 4, 5. There will be 5 holes along the left-hand side given position numbers 6, 7, 8, 9, 10. We will be using 6 pin holes only that will be 2, 3, 4, (RH ide) and 7, 8, 9 (LH ide). It therefore follows that you can permutate 3 side pins into any 6 holes. There are a total of 20 permutations. These permutations will be used on cylinder profiles E153, E305 & AB. This therefore gives a total of 60 variations. Cylinder profile E218 will not be used in the side pin format, thus giving a limited capacity to use side pin and ordinary profile on one suite. ide pin cylinders will have no less than and no more than 3 side pins. 17
ide pin keys will have corresponding dimples drilled into the side thus allowing the side pins to locate correctly and the plug to rotate. hould a key with the wrong side pin permutation or a key with no side pin cuts at all can be used then this will push the side pins outward into grooves cut into the inner bore of the cylinder and stop the plug from rotating. It now follows that a key will require a minimum of 3 dimples cut into the side in the correct positions to allow the plug to rotate. To facilitate extra suiting we shall cut dimples into the key in permutations of 3, 4, 5 & 6. There are a total of 39 permutations per key section and we are using 3 key sections, that are H1 (Master Key ection), E153 and E305. This gives a total of 117 variations of side pin key. Key profiles E218 will not be used in the side pin format thus giving a limited capacity to use side pin and ordinary profile cylinders on one suite. There are more key variations than cylinder variations and will therefore increase suiting capacity/complexity. 18 At present all Pro-Key suites are generated on suite development software. On the key and cylinder pages there is only enough space for a 3-digit key/cylinder profile. This means that the key profiles (117 side pin profile and E218 standard profile) will require short codes. The short codesalong with the actual code and key profile are itemised on the following lists A & B.
Pro-Key ide Pin Pro-Key ide Pin A X1 A1 B1 C1 D1 E1 F1 1A 1B 1C 1D 1E 1F 1 1H 1J 1K 1L 1M A1 B1 C1 D1 E1 F1 1 J1 K1 L1 M1 N1 P1 Q1 R1 1 T1 U1 V1 W1 5X3 5A3 5B3 5C3 5D3 5C3 5F3 53A 53B 53C 53D 53E 53F 53 53H 53J 53K 53L 53M OX5 OA5 =roup =ervant HORT CODE OB5 OC5 OD5 OE5 OF5 05A 05B 05C 05D 05E 05F 05 05H 05J 05K 05L 05M A53 B53 C53 D53 E53 F53 53 H53 J53 K53 L53 M53 N53 P53 Q53 R53 53 T53 U53 V53 A05 B05 C05 D05 E05 F05 05 H05 J05 K05 L05 M05 N05 P05 Q05 R05 05 T05 U05 V05 =roup =ervant HORT CODE C C C C C C C C C C C C C C C C C C C C A53 B53 C53 D53 E53 F53 53 H53 J53 K53 L53 M53 N53 P53 Q53 R53 53 T53 U53 V53 A05 B05 C05 D05 E05 F05 05 H05 J05 K05 L05 M05 N05 P05 Q05 R05 05 T05 U05 V05 AAB BAB CAB DAB EAB FAB AB HAB JAB KAB LAB MAB NAB PAB QAB RAB AB TAB UAB VAB =roup =ervant HORT CODE Pro-Key ide Pin hort Codes - Keys Cylinders 19
Pro-Key ide Pin elect the product to be ordered. Make a copy of the ide-pin short code list (overleaf) Note the product code/s of the item/s to be ordered on your order sheet. The same code must be repeated if different profiles for the same product are to be ordered. Using for reference the pages from this manual headed ide-pin hort Codes-Cylinders, select a short code which corresponds to your chosen section (e.g. hort code 5A3 corresponds only to an E153 Key section). Write the chosen short code next to the product code in the line of the order. When ordering key-blanks, repeat this process, this time using ide-pin hort Codes-Keys and write your chosen short code. Make sure that the short key code refers to the same key section (e.g. E305) of the cylinder that the keyblank is being ordered for. imply fax a copy of the completed order form to us on the number at the top of the page. PLEAE NOTE: ide-pin parts are the same as non side-pin parts, so will not need to be ordered separately. Always send your Pro-key fax header showing your dealer number, order number and company name, with every order. Part No. Description Quantity Keys Locks (Packs) 854835604024 E3010B /Assy E153 1 C53 894833920001 Pad 6 K /Assy E153 1 53 894833920001 Key-blank E153 1 C53 20
Component Parts ingle Euro Profile, Double Euro Profile, Key & Turn Euro Profile Pin No Reference 1 843325186001 2 843325187001 3 843325188001 4 843325189001 5 843325190001 6 843325191001 7 843325192001 8 843325193001 9 843325194001 10 843325195001 MK Discs No Reference 2 843328315001 4 843328317001 6 843328319001 8 843328321001 Drivers (td) No Reference 2.4 843321108001 4.8 843321110001 pring No Reference 1 843117132001 topper Finish Reference 5mm Brass 843614126024 21
Assembly Instructions ingle Euro Profile, Double Euro Profile, Key & Turn Euro Profile tep One With the housing inverted and the key inserted. Insert the cylinder pins (there are 10 sizes available the smallest being (1) and the largest (10)) in hole number sequence 1 to 6 (front of plug to back). Examine your pinning chart, read off the correct pin size and then insert the pin into the corresponding hole. ee Example 1. tep Two Plug Hole Numbers 4, 5, 6 need Topping Up with master key discs, there are four sizes of disc and the choice is a matter of referring to your master bitting chart. ee example 2. tep Three The cylinder now has to be loaded with drivers and then springs, (all drivers are the same length). Example 1: MK 737351 Key Differ 737513 Pin Numbers 737311 Plug Hole Numbers 123456 Into; Hole We Insert Pin ize No.1 7 No.2 3 No.3 7 No.4 3 No.5 1 No.6 1 Example 2: Hole No.4 No.5 No.6 Insert Disc No.2 No.4 No.2 tep Four Hold down the elements as shown in the drawing below using the dummy stoppering tool and test key operation. ee drawing opposite. tep Five Insert and rivet the stoppers using the fixture provided. For a double cylinder repeat steps 1 to 5. tep ix Lubricate with Triflow 22
Component Parts Pin No Reference 1 843325186001 2 843325187001 3 843325188001 4 843325189001 5 843325190001 6 843325191001 7 843325192001 8 843325193001 9 843325194001 10 843325195001 MK Discs No Reference 2 843328315001 4 843328317001 6 843328319001 8 843328321001 Drivers (td) No Reference 6 843321904001 pring No Reference 1 843117132001 topper Finish Reference 5mm Brass 843614126024 23
Assembly Instructions ingle Oval, Double Oval, Key & Turn Oval Profile tep One With the housing inverted and the key inserted. Insert the cylinder pins (there are 10 sizes available the smallest being (1) and the largest (10)) in hole number sequence 1 to 6 (front of plug to back). Examine your pinning chart, read off the correct pin size and then insert the pin into the corresponding hole. ee Example 1. tep Two Plug Hole Numbers 4, 5, 6 need Topping Up with master key discs, there are four sizes of disc and the choice is a matter of referring to your master bitting chart. ee example 2. Example 1: MK 737351 Key Differ 737513 Pin Numbers 737311 Plug Hole Numbers 123456 Into; Hole We Insert Pin ize No.1 7 No.2 3 No.3 7 No.4 3 No.5 1 No.6 1 tep Three The cylinder now has to be loaded with drivers and then springs, (2.4 or 4.8 No. drivers are required). Example 2: Hole No.4 No.5 No.6 Insert Disc No.2 No.4 No.2 tep Four Hold down the elements as shown in the drawing below using the dummy stoppering tool and test key operation. ee drawing opposite. tep Five Insert and rivet the stoppers using the fixture provided. tep ix Lubricate with Triflow 24
Rim Component Parts Pin No Reference 1 843325186001 2 843325187001 3 843325188001 4 843325189001 5 843325190001 6 843325191001 7 843325192001 8 843325193001 9 843325194001 10 843325195001 MK Discs No Reference 2 843328315001 4 843328317001 6 843328319001 8 843328321001 Drivers (td) No Reference 2.4 843321108001 4.8 843321110001 pring No Reference 1 843117120001 topper Finish Reference 5mm Brass 843614126024 NP 843254139164 NP 843254139164 843721128001 25
Assembly Instructions tep One Insert the cylinder pins, master key discs, drivers and springs. By examining your pinning chart load hole No.6., (Hole No.6. is nearest to the connecting bar). lide on the sleeve to cover that hole. Repeat this for holes 5, 4, 3 and 2. (Pin numbers 1-5 use drivers 4.8 and pin numbers 6-10 use drivers 2.4) tep Two Pull sleeve back until the two anti drill plates can be inserted, then slide the sleeve on until the anti drill plates are retained. Hole number 1 can then be loaded, and the sleeve pushed fully home. tep Three Remove the cylinder from the assembly fixture and try key operation. If satisfactory, the cover plate needs to be retained, this is achieved by using the Jig and Punch - see drawing opposite. tep Four Lubricate with Triflow 26
Component Parts candinavian Parts 27
Assembly Instructions candinavian Parts tep One With the housing inverted and the key inserted. Insert the cylinder pins (there are 10 sizes available the smallest being (1) and the largest (10)) in hole number sequence 1 to 6 (front of plug to back). Examine your pinning chart, read off the correct pin size and then insert the pin into the corresponding hole. ee Example 1. tep Two Plug Hole Numbers 4, 5, 6 need Topping Up with master key discs, there are four sizes of disc and the choice is a matter of referring to your master bitting chart. ee example 2. tep Three The cylinder now has to be loaded with drivers and then springs, (2.4 or 4.8 No. drivers are required). Example 1: MK 737351 Key Differ 737513 Pin Numbers 737311 Plug Hole Numbers 123456 Into; Hole We Insert Pin ize No.1 7 No.2 3 No.3 7 No.4 3 No.5 1 No.6 1 Example 2: Hole No.4 No.5 No.6 Insert Disc No.2 No.4 No.2 tep Four Hold down the elements as shown in the drawing below using the dummy stoppering tool and test key operation. ee drawing opposite. tep Five Insert and rivet the stoppers using the fixture provided. tep ix Lubricate with Triflow 28
Component Parts crew-in Mortice Cylinder 29
Assembly Instructions crew-in mortice cylinder Insert the cylinder pins, master key discs, drivers and springs. (Pin numbers 1-5 use drivers 4.8 and pin numbers 6-10 use drivers 2.4) By examining your pinning chart load hole No. 6. (hole No.6. is the hole nearest the cam) slide on the cover plate to cover that hole. Repeat until all six holes are full. Try key operation. If satisfactory the cover plate needs to be retained, (see drawing opposite) taking care not to damage the thread. Lubricate with Triflow 30
Component Parts Pin No Reference 1 843325186001 2 843325187001 3 843325188001 4 843325189001 5 843325190001 6 843325191001 7 843325192001 8 843325193001 9 843325194001 10 843325195001 MK Discs No Reference 2 843328315001 4 843328317001 6 843328319001 8 843328321001 Drivers (mall) No Reference 2.4 843321108001 4.8 843321110001 pring (mall) No Reference 1 843117120001 Cover Plate Finish Reference 1 843765106001 Tab Washer 1 842131101001 Locking Nut (M10) 1 843754515001 31
Assembly Instructions Cam Lock tep One Insert the cylinder pins, master key discs, drivers and springs. (Pin numbers 1-5 use drivers 4.8 and pin numbers 6-10 use drivers 2.4) By examining your pinning chart load hole No. 6. (hole No.6. is the hole nearest the cam) slide on the cover plate to cover that hole. Repeat until all six holes are full. tep Two Remove cylinder from the fixture and try key operation. If satisfactory the cover plate needs to be retained, (see drawing opposite) taking care not to damage the thread. tep Three The cam retained by using a 10mm nut and tab washer. tep Four Lubricate with Triflow 32
Component Parts Padlock/Knobset Cylinder Pin No Reference 1 843325186001 2 843325187001 3 843325188001 4 843325189001 5 843325190001 6 843325191001 7 843325192001 8 843325193001 9 843325194001 10 843325195001 MK Discs No Reference 2 843328315001 4 843328317001 6 843328319001 8 843328321001 Drivers (mall) No Reference 2.4 843321108001 4.8 843321110001 pring (mall) No Reference 1 843117120001 toppers Finish Reference 5mm 843614126024 33
Assembly Instructions Padlock/Knobset Cylinder tep One Insert the cylinder pins, master key discs, drivers and springs. (Pin numbers 1-5 use drivers 4.8 and pin numbers 6-10 use drivers 2.4) By examining your pinning chart load hole No. 6. (hole No.6. is the hole further away from the key bow) slide on the cover plate to cover that hole. Repeat until all six holes are full. tep Two Remove the cylinder from the fixture and try key operation tep Three Insert and rivet the stoppers using the stoppering punch provided. tep Four The cylinder is now ready for use with a padlock body. tep Five Lubricate with Triflow 34
Bronze Padlocks 840/841, 850/851 Padlocks 35
36 Bronze Padlocks
Bronze Padlocks 840/841, 850/851 Padlocks 840 Body & hackle 894833335027 5 841 Body & hackle 894833355027 5 850 Body & hackle 894833336027 5 851 Body & hackle 894833346027 5 850 Long hackle 2 Body & hackle 894833348027 5 851 Long hackle 2 Body & hackle 894833349027 5 840 teel hackle 893363104162 10 841 Bronze hackle 893363206027 10 850 teel hackle 893363105162 10 851 Bronze hackle 893363207027 10 850 2 teel hackle 893363107162 10 851 2 Bronze hackle 893363209027 10 870 Body & hackle 894833338027 5 871 Body & hackle 894833347027 5 870 teel hackle 893363110162 10 870 Bronze hackle 893363212027 10 PAD PK K Body elf Assembly E153 894833920001 5 PAD PK K Body elf Assembly E305 894833921001 5 PAD PK K Body elf Assembly E218 894833940001 5 PAD PK K Body elf Assembly AB 894833922001 5 37
Assembly Instructions Bronze Padlocks tep One Assemble cylinder as per the instructions on the previous pages. tep Two Liberally grease the bottom of the padlock bore forcing grease into the two cross holes. Take one 2.5mm ball bearing and drop it into the padlock body from the underside and push it into the cavity (long shackle leg side). Then drop the cam into the body with the tailpiece uppermost and at such an angle so as to put the release scollops in the vertical plain. 38
Assembly Instructions Bronze Padlocks With a pair of tweezers place the cam spring on top of the cam in such a way so that the short leg slides down the cut out in the cam and the long leg is pointing upwards and biased to the side wall of the body cut out. Drop the inner cylinder assembly into the padlock body. If it does not seat properly, insert a key and rotate slightly in each direction until the cylinder aligns with the cam and drops into place, then gently remove the key. Locate the retaining plate onto the base of the body. Now apply some grease to the anti drill ball bearing and push it into the retaining nut, and drop this into the retaining plate. 39
Assembly Instructions Bronze Padlocks tep ix Hold the retaining nut and plate in place and turn the padlock the correct way up. Using a No.1. Posi-drive screw driver locate the retaining plate retaining screw into the retaining nut, down the long shackle leg chamber, and tighten. The retaining plate should now hold the inner cylinder into the padlock. tep even Drop the shackle spring into the long shackle leg chamber and the remaining ball bearing into the open hole. ee Illustration 1. tep Eight Put the key into the padlock and turn to allow the ball bearing to retract. Lightly apply grease around the shackle bore pockets and the shackle retainer and push the shackle into place (long shackle leg on retaining pin side) and release the key. ee illustration 2. tep Nine The shackle can now be retained using the M4 x 5mm dog point screw. tep Ten The padlock should now be operated to check that the shackle is sprung open and can be clicked back into the locked position and the key removed. 40
Harsh weather & Lubrication Harsh Weather Applicatons & Lubrication of Pro-Key Cylinders Harsh Weather and Coastal Applications In the interest of continuous improvement, Yale pro-key pins are now nickle-plated as standard. This will help to protect the steel surface of the pins from degration, either when held in stock or in situ within a cylinder chamber. We are aware that Pro-Key cylinders are already in use across the U.K., in towns and cities and also in the countryside and near to the coast. For those cylinders that are likely to be exposed to either harsh climatic conditions, or for coastal applications, we recommend the use of nickel silver pins (as opposed to nickel plated pins). These pins have been tested with salty spray for durability and anti-corrosive properties and are available now as an alternative component. Please contact the Yale master-key department for details. Lubrication Yale recommend the use of Triflow for the lubrication of all Pro-Key cylinders. Lubrication must be carried out both when cylinders are first assembled, and as part of routine maintenance. 41
Delivery Times Delivery lead times for assembled cylinders on applications Normal Orders Delivery Time tandard izes Offset Cylinder Additional Charges Up to 5 days Please check availablility with customer services None Criteria Minimum order value 100 Master key direct lines: Tel: 0845 302 4765 Fax: 01902 364054 (Orders only) 42
Customer Documentation Important Customer Information The Yale Pro-Key system is protected by a UK patent. Only Yale appointed Pro-Key dealers are authorised by Yale to cut additional or replacement keys for the Pro-Key system. Only Yale appointed Pro-Key dealers are authorised to provide extentions to Pro-Key master-key suites. For additional or replacement cylinders and keys, please contact the dealer who supplied your original system. If you are unsure which Pro- Key dealer supplied your system please contact the Yale master-key department, ensuring that you have a Pro-Key from your system to hand. ecurity Products UK Limited Customer ervice Department chool treet Willenhall WV13 3PW Tel: 0845 302 4765 Fax: 01902 364054 (Orders Only) 43
ales Tools o to www.yale.co.uk where you will find Pro-Key dealer search facility downloadable Pro-Key sales literature master key contacts up to date product information 44