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1. 024B INSTRUCTION MANUAL IMPORTANT Read these instructions before you use your new 024B Key Machine Ensure that all safety recommendations are followed See page 2 for instructions MAA UM MT U This manual is registered and applies specifically to the machine which carries this serial number It properly identifies your model and assures you will receive correct parts if and when you require replacement parts Retain this manual in a safe place It s the only one of its kind If ownership of this machine is transferred this service manual should accompany the machine When seeking service information about this machine refer to Model No 024B and the part number desired see pages 6 to 8 Note that many parts are not interchangeable with other ILCO UNICAN machines CONTENTS Wallanty soria Safety information seine Introduction unpacking Operating parts illustrated Operating parts identification names and part numbers 5 Exploded view ee O cd 6 Exploded view parts IE 8 Operating handles test keys key cutting neuen 9 How t duplicate vs neun ie 10 The cutting OPETA ON saa ea 0 11 Replacing the cut anne 12 A A O W W EEE ERR EAST 13 ONE YEAR LIMITED WARRANTY ILCO UNICAN warrants to the original buyer of any new model 024B machine that it will repair or replace at its option any part of any machine which proves to the reasonable satisfaction of ILCO UNICAN to have defects arisi2. 114 024B 114 Torque arm 47 024B 47 Motor pulley 2 3L 115 024B 115 Shoulder screw 48 024B 48 V Belt 3L 180 160 024B 160 Caution label 49A 024B 49A Cutter guide stylus 171 024B 171 Cutter pulley set screw 18 50 024B 50 Cutter guide roller 177 024B 177 Ext retaining Ring 51 024B 51_ Guide roller bushing 178 024B 178 Washer 52 024B 52 Socket head screw 8 32 X 1 179 024B 179 10 32 x 3 4 SCHS 53 024B 53 Cutter guide binding washer 180 024B 180 Mount Plate 54 024B 54 Cutter guide binding screw 181 024B 181 Key Gauge Spacer Left 55 024B 55 Adjusting screw 182 024B 182 Key Gauge Spacer Right 183 024B 183 1 4 20 Lockwasher 184 024B 184 1 4 20 Hex Nut 185 024B 185 Plate Chip Guard IM 024B IM Instruction manual NS 024B 240 220V HP motor co OPERATING HANDLES TEST KEYS KEY CUTTING Operating handles The 024B key machine is shipped completely assembled except for the carriage handle and the lever handle Upon unpacking the machine locate the carriage handle and thread it into the carriage in the area directly above the trigger assembly Then cut the nylon band holding the carriage rigid and insert the lower end of the lever handle into the hole in the pinion shaft located at the front of the machine on the left side Tighten the set screw on the front of the pinion shaft to secure the lever handle Refer to page 5 if uns
3. damaged or worn cords W INTRODUCTION UNPACKING Congratulations You ve purchased a superior key cutting machine The Model 024B semiautomatic key machine you ve just purchased incorporates the latest improvements in de sign for key duplicating machines of its type The semiautomatic function of the 024B means that the machine itself supplies the proper degree of pressure against the machine s carriage during the key duplication process and that the tracing motion of the carriage while duplicating a key is controlled by simply moving a lever In essence the model 024B duplicates keys with more consistent accuracy and greater speed especially important in situations where several employees operate the machine during the course of the day Featuring exclusive four way vise jaws the model 024B is designed to accommodate virtually any standard cyl inder key without the need for adapters Even double sided automotive keys can be duplicated with ease the four way jaws include stations ideally suited to gripping these keys and is capable of gripping them in the groove or milling for enhanced clamping performance when necessary See illustration on page 10 Unpacking instructions Your 024B key machine has been shipped to you in a sturdy specially cushioned container to prevent the pos sibility of damage during handling and shipment Once the machine is removed from the carton it should be set up on a level workb
4. YY eh U USA ILCO UNICAN CORP 400 Jeffreys Rd Rocky Mount NC 27802 2627 Tel 919 446 3321 e 919 446 4702 After March 22 1998 area code changes to 252 Canada and international ILCO UNICAN INC 7301 Decarie Blvd Montreal Quebec H4P 2G7 Tel 514 735 5411 e 514 735 4704 Export Fax 514 735 1393 Printed in USA 125000
5. lie flat across the entire width of each vise jaw Neither key should be tilted 2 Do NOT use pliers or other tools to tighten the vise jaws Firm hand pressure is sufficient 3 Keep the carriage shaft free of metal chips A thin film of oil can be applied to it The carriage should be free to move without binding 4 NEVER touch the shoulder of a key to the side of the cutter guide This will cause the shoulder of the key blank to touch the side of the cutting wheel When this happens some of the metal will be cut away from the shoulder of the key blank If the resulting duplicated key is duplicated two three four times over an error will accumulate and cause a non operating key Do not grind away the shoulder 5 Don t run the cutter into the vise jaw this will dull the cutter and reduce cutter efficiency 6 Keep the cutter clean Don t let any foreign objects or instruments blunt it This cutter is a precise cutting tool and should be handled with care 7 Lubricating of moving parts is important An oil cup is provided to keep the cutter shaft bearings well lubricated 5 7 drops of 3 in 1 or lightweight spindle oil in the oil cup is sufficient The carriage spindle should be lubricated with a thin film of oil and wiped free of chip build up The lubrication procedures should be performed every 2 3 weeks depending on usage The motor requires lubrication on an annual basis See motor label for details 14 15 16 MAT
6. of the jaw X Ideal for holding most double sided convenience keys used on most current automobiles Grip these keys by the grooves rather than the blade edge where the cuts are located see Fig 2 Figure 2 Super Jaw 2 vise jaw shown gripping a typical automotive key 8 Using standard position ESA Using X position To reposition the vise jaws as from Standard to Wide Using wide position Using narrow position first loosen the wing nuts Then lift upward on the top and bottom of each vise jaw as a complete unit to raise them above their seat in the carriage Rotate the jaws until the chosen vise position is facing toward the rear of the machine and lower the jaws back into contact with the carriage Both left and right vise jaws should be rotated to the same position EXPLODED VIEW EXPLODED VIEW PARTS LIST Refer to pages 6 7 for illustration Ref Part no Description Ref Part no Description 1 024B 1 Carriage 56 1024B 56 Key gauge 1X 024B 1X Carriage assembly 57 024B 57 Key gauge bracket 2 024B 2 Carriage stud 58 024B 58 Key gauge dowel pin 3X 024B 3X Vise jaw assembly 59 024B 59 Key gauge housing two 4 024B 4 Vise jaw spring 60 024B 60 Cap screw 8 32 x A 6X 024B 6X Thrust bearing set 61 024B 61 Circuit Breaker ETA 1658 8 024B 8 Wing nut 62A 024B 62A On Off switch
7. 9X 024B 9X Carriage handle assembly 68 024B 68 Electrical cover 11X 024B 11X Trigger assembly 70 024B 70 Rubber Mount 16 024B 16 Carriage torsion spring 74 024B 74 Truss head screw 8 32 17 024B 17 Washer 75 024B 75 Motor 4 hp 115V C S 18 024B 18 Screw 10 32 x 4 79 024B 79 Key gauge spring 20 024B 20 Cutter shaft bushing 82 024B 82 Oil cup 21 024B 21 Carriage shaft bushing 84 024B 84 Crescent ring 23A 024B 23 Carriage shaft 85 024B 85 024B 110V nameplate 24 024B 24 Pivot Block 86 024B 86 Safety hood 25 024B 25 Pinion shaft bushing 86X 024B 86X Safety hood assembly 28A 024B 28 Pinion shaft 87 024B 87 Safety shield 29A 024B 29A Set screw 4 20 x Yo 88 024B 88 Shield screws 10 32 x 32 024B 32 Socket hd screw 10 24 x 89 024B 89 Flat washer 10 34 024B 34 lockwasher 90 024B 90 Nut 10 32 35 024B 35 Carriage lever 91 024B 91 Power cord 35X 024B 35X Carriage lever assembly 92 024B 92 3 wire motor cable 36 024B 36 Cutter nut N 4 101 024B 101 Motor pulley set screw 37 024B 37 Cutter spacer 106 024B 106 Chip Tray 38 024B 38 CU20 cutter 109 024B 109 Bearing washer 40A 024B 40A Cutter shaft 110 024B 110 Wave washer 41 024B 41 Cutter shaft pulley 111 024B 111 024B Yoke 43 024B 43 Nylon brush 112 024B 112 Socket head screw 10 32 x Y 45 024B 45 Brush bolt washer 113 024B 113 Roll pin 46A 024B 46A Hex head screw 6 18 x
8. assure that a proper match has been made Ensuring both four way vise jaws have been placed in the proper position for the type of key to be duplicated See Using the four way vise jaws sec tion of this manual Proper alignment of the pattern key and blank key within the vise jaws See Aligning keys in the vise jaws Actual duplication of the pattern key which can be properly accomplished only after the previous steps are performed N w A Using the four way vise jaws Your 024B is equipped with the ILCO UNICAN versatile Four way Super Jaw 2 vise jaws They feature four unique clamping surfaces to securely grip virtually any typical cylinder key see Fig 1 Figure 1 STANDARD PR Rotate both jaws as a set 10 Using the four way vise jaws cont To obtain the best gripping action possible it is necessary to assure that the proper vise jaw position is selected for each key you duplicate The vise positions are explained below and proper usage shown in figure 2 Standard for holding regular cylinder keys such as house keys single sided automotive keys padlock keys with one or two shoulders Narrow for holding the 1092B and other narrow width keys Wide for holding the Ford double sided keys and similar types either primary or secondary When posi tioning the keys in the vise jaws lay the key so that its center ledge is flat against the top surface
9. e Tighten the jaws wing nut securely 3 Move the carriage lever to the left so that the key gauge s right hand finger with the gauge lowered is just forward of the key blank s tip 4 Insert the customer s key pattern key in a similar manner in the left hand jaw Then position both the customer s key and the key blank so that their tips are both in direct contact with the left edge of the key gauge fingers see figure 6 Figure 6 SZ ZEE 5 After both the customer s key and blank key are aligned lift key gauge to its raised position 6 If a key is cut on both sides after duplicating side one rotate and proceed with side two using the same alignment procedure In the case of Ford keys as well as most doublesided European and Japanese double sided keys only the blank needs to be rotated as the cuts are the same on both sides 7 Refer to page 12 for additional information covering the actual key duplicating process 11 HOW TO DUPLICATE KEYS General key duplication procedures WARNING Do not install or remove keys unless the off on switch is in the OFF position Always wear eye protection when operating this machine There are four procedures that the machine operator performs to insure proper duplication of a key 1 Selection of the proper key blank Compare the head length and key blank s cross section width angle and location of grooves with the key to be duplicated to
10. e key gauge must be fitted to the machine after it has been installed To do this first install a pattern key and key blank and align these against the cutter guide and cutter Then lower the key gauge and file the appropriate finger of the gauge to allow contact with the shoulder of both keys Adjusting the Carriage Stop The purpose of the carriage stop is to prevent the cutter from hitting into the right vise jaw The stop is a nut and bolt and is adjustable see Fig 11 To check the adjustment raise carriage without keys in vise jaws and rotate the cutter by hand The cutter should not contact the vise jaw When the carriage stop is properly adjusted there should be a space of 008 between the vise jaw and the cutter this is about the thickness of an ordinary business card Do not allow a greater distance since this may affect the depth of cut Cleaning Your machine should be kept clean of all filings and dust The most critical areas are the carriage jaws and shafts A one inch paint brush is ideal to brush these areas of the machine The shafts should be wiped periodically with a lightly oiled cloth We suggest brushing the jaws often as even a single filing can alter the accuracy of the machine Lubrication Intervals Lubricating of moving parts is important An oil cup is provided to keep the cutter shaft bearings well lubricated 5 7 drops of 3 in 1 or lightweight spindle oil in the oil cup is sufficient The carriage
11. ench and wiped free of all rustproof ing oil The machine is adjusted at the factory and test keys have been cut on it but it is recommended that you check the adjustments to make sure they have not slipped or shifted during transit see page 13 Adjusting for depth of cut Safety The 024B has been engineered to duplicate cylinder paracentric keys It is not intended or designed for any other purpose The machine operator assumes all liabili ty when using this machine in a manner inconsistent with its stated design purpose Refer to page 3 for complete safety information before operating the machine ILCO UNICAN strongly recommends the use of protec tive eye glasses or goggles when operating this machine CAUTION or when in the vicinity of the machine while it is being operated Protective eye wear prevents injuries The machine should be turned off before loading or unload ing keys When the key machine is operating be careful not to contact the vise jaw or carriage against the cutting wheel as this will cause damage to the cutter jaw or carriage DO NOT DESTROY OR DISCARD THIS VALUABLE SHIPPING CARTON STORE IT CAREFULLY IN A SAFE PLACE THIS CARTON SHOULD BE USED WHENEVER THE MACHINE IS MOVED OR SHIPPED ADJUSTMENTS Adjusting for depth of cut To ensure safety UNPLUG machine from its power source before adjusting for depth of cut It s imperative that the key guide and the cutter be in the same
12. er Install the new cutter the washer and the nut Cutter guide stylus Carriage lever assembly Key gauge Circuit Breaker On Off power switch Operating parts identification Part no 024B 1 024B 3X 024B 8 024B 9X 024B 11X 024B 35X 024B 38 024B 43 024B 49A 024B 56 024B 61 024B 62A 024B 82 024B 86X 024B 87 Identification Carriage Vise jaw assembly Wing nut Carriage handle assembly Trigger assembly Carriage lever assembly CU20 cutter Nylon brush Cutter guide stylus Key gauge Circuit Breaker On Off power switch Oil cup Safety hood assembly Safety shield Vise jaw assembly OPERATING PARTS Safety hood Safety shield assembly Oil cup Nylon brush cu20 Cutter Wing nut Trigger assembly Carriage Carriage handle assembly EXPLODED VIEW THE CUTTING OPERATION Aligning keys in the vise jaws Keys with shoulders WARNING Do not install or remove keys unless the off on switch is in the off position Both the pattern key and the key blank must be proper ly aligned and securely clamped in the vise jaws prior to duplication The correct procedure to do this follows 1 Move the carriage lever to the left as far as possible See Fig 3 Figure 3 Figure 4 2 Assure that both vise jaws are rotated to the correct position for the type of key be
13. ing duplicated 3 Place the key blank in the right hand jaw Position it so that it is parallel with the front portion of the jaw See Fig 4 Tighten wing nut lightly 4 Swing key gauge down to rest on the blade of the key blank Slowly move carriage lever clockwise to the right until the shoulder of the key blank butts up against the edge of the key gauge See Fig 5 5 Use index finger to press down on the front edge of the key blank while loosening wing nut Retighten securely after assuring that the key blank is contact ing key gauge and is properly seated in the vise jaw 6 Position pattern key in the left vise jaw repeating the procedure described in step 4 Figure 5 7 Check to ensure that the pattern key and blank key s shoulders are snug against the key gauge and both keys positioned level not tilted in the vise jaws Return key gauge to the up position The key is now properly aligned for duplication Aligning keys in the vise jaws Keys without shoulders On keys that don t have a conventional shoulder such as the Ford doublesided key the tip of the key is used as the aligning point With keys of this type follow this procedure 1 Assure that both vise jaws are rotated to the correct position for the type of key being duplicated 2 Position the key blank in the right hand jaw For most tip gauged automotive keys position the blank so that the tip is roughly 1 4 left of the jaws right edg
14. ject to potential injury from flying chips Do not defeat safety features built into your machine Removal or modification of safety shields cutter guards and other safety devices should be strictly forbidden Electrical safety 120 Volt models Your machine is designed to operate using 120 Volt A C 60 Hz electrical current It is supplied with a three prong power plug which should be used with a properly grounded three prong outlet only Do not defeat the safety purpose of the plug by modifying or using with non grounded outlets To reduce risk of fire or electrical shock do not expose or operate machine in damp or wet locations Grounding instructions In the event of a malfunction or breakdown grounding provides a path of least resistance for electric current to reduce the risk of electric shock This machine is equipped with an electric cord that has an equipment grounding conductor and a grounding plug The plug must be plugged into a machine outlet that is properly installed and grounded in accordance with all local codes and ordinances Do not modify the plug provided if it will not fit the outlet have the proper outlet installed by a qualified electrician Improper connection of the equipment grounding conductor can result in a risk of electric shock The conductor with insulation that has a green outer At no time should the mechanically driven parts of the machine be touched while it is in operation The
15. mponent thereof is warranted irrespective of whether or not payment is eventually made These warranties are in lieu of and not in addition to any other warranty of condition expressed or implied including without limitation merchantability fitness for a particular purpose or latent defects The buyer releases ILCO UNICAN from any liability for any reason other than a breach of its warranties hereunder The liability of ILCO UNICAN shall in no case including negligence exceed the purchase price of the defective machine nor shall ILCO UNICAN be liable for any personal injuries property damage or consequential damages Use only genuine ILCO UNICAN replacement parts on this machine Serial number WARNING SAFETY NOTICE IMPORTANT Please read carefully before operating machine Safety begins with education and continues with proper application All personnel who operate your machine should read the supplied Operators Manual for information on how to properly operate it The likelihood of accidents and miscuts will be greatly reduced General safety Safety glasses must be worn to reduce the possibility of eye injury while operating or in the immediate vicinity of key cutting equipment Always turn machine off before making adjustments or inserting or removing keys Machine should be located in an area accessible only by authorized operators Location must be such that customers and other personnel are not sub
16. ng from the faulty manufacture of the machine or from defective material or components during a period of one 1 year from the date of shipment of the machine by ILCO UNICAN provided that the machine is returned by prepaid transport to ILCO UNICAN or to its authorized representative before the expiry of the warranty period together with a detailed description of the alleged defect s ILCO UNICAN may at its discretion elect to refund the purchase price allowable to the part affected or to issue a credit if the price therefore remains unpaid ILCO UNICAN sells precision made machines The buyer assumes all risks and ILCO UNICAN shall not be liable for any reason if the machine has been subjected to improper installation improper use improper or inadequate maintenance negligence if any unauthorized modification or alteration is made to the machine or in case of accident For greater certainty any machine not operated in accordance with ILCO UNICAN s printed instructions or operated beyond its rated capacity shall not be covered by this or any other warranty Any and all warranties made by ILCO UNICAN on any machine product or component thereof shall be effective only if and for so long as the buyer complies with all payment obligations pursuant to the buyers accepted and acknowledged order Failure to meet such payment obligations shall void all warranties and not extend the period of time for which such machine product of co
17. operator should take care to ensure that loose fitting clothing long hair etc are kept from the area of machine operation Your machine has been specially designed and built for key cutting purposes only and should be operated according to the Operators Manual All other uses are strongly discouraged as potentially dangerous and should not be attempted Such use will immediately void the machine s warranty Some states have specific age restriction concerning the operation of certain types of equipment Check local and state ordinances for compliance Electrical problems should be referred to qualified repair technicians If the machine is under warranty contact ILCO UNICAN at the address printed on the cover ILCO UNICAN also offers repair service for out of warranty machines Contact ILCO UNICAN for details Always unplug the machine before removing the hood or changing the cutter wheel surface with or without yellow stripes is the equipment grounding conductor If repair or replacement of the electric cord or plug is necessary do not connect the equipment grounding conductor to a live terminal Check with a qualified electrician or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the machine is properly grounded Use only 3 wire extension cords that have 3 prong grounding plugs and 3 pole receptacles that accept the machine s plug Repair or replace immediately
18. plane that is aligned to each other If the cutter guide protrudes further than the cutter the resulting cuts in a key blank will be too shallow and the duplicate key will not work Likewise if the cutter guide is behind the cutter the cuts in the key will be too deep see Fig 9 Figure 9 Adjustment is correct when both key blanks touch 7 To check the depth adjustment insert two identical key blanks into the vise jaws setting them flat in each vise It is not necessary to align the blanks Then raise the carriage positioning the left blank against the cutter guide and the right blank against the cutter Next turn the machine pulley by hand and note the right key blank The cutter should just barely graze the key blank when the adjustment is correct No cutter is perfectly round so make one complete rotation of the cutter before changing adjustment There will be a high point on the cutter the adjustment should be made to the high point If the cutter does not touch the key blank after one rotation proceed to change the adjustment To adjust cutter guide loosen the binding screw on top of the guide With a flat screwdriver turn adjusting screw in to increase depth and or out to decrease depth See Fig 10 Figure 10 Binding Adjusting screw Depth of Cut Adjusting for spacing There is no adjustment for spacing However if a key gauge assembly is ever replaced th
19. spindle should be lubricated with a thin film of oil and wiped free of chip build up The lubrication procedures should be performed every 2 3 weeks depending on usage The motor requires lubrication on an annual basis See motor label for details Circuit Breaker To protect against machine damage X in the unlikely event the unit jams while duplicating a key your 024B is equipped with a circuit breaker CIRCUIT BREAKER Should it activate turn the power switch to the off position pull the carriage back to the load position and press the circuit breaker button in to reset At this point the machine will run once the power switch is again placed in the on position Repeat the cutting procedure to complete the unfinished duplicate 13 THE CUTTING OPERATION REPLACING THE CUTTER General operating sequence WARNING Do not install or remove keys unless the off on switch is in the off position Always wear eye protection when operating this machine 1 Rotate both vise jaws to the station suitable for the key being duplicated Insert the blank key and pattern key into the vise jaw using the appropriate method described under Aligning keys in the vise jaws Be sure that both keys are laying level in the vise jaws and are not tilted N WW After the keys are aligned move the car riage lever to the right clockwise until the cutter guide is slightly left of the cut close
20. st to the head of the pattern d i key See Fig 7 Press the off on switch to the ON position Push down on the Figure 7 Ha ul carriage handle while pulling out on the carriage trigger See Fig 8 Figure 8 Trigger pull out to release This will allow you to ease the carriage up into cutting position Take care to ensure that the carriage does not slam forward as this will result in probable cutter damage Remember best results are obtained if the cutter guide makes initial contact slightly left of the cut closest to the head of the pattern key Do not permit the cutter to touch the shoulder of the key blank 12 General operating sequence cont 6 The carriage movement is controlled by the carriage lever Using slow to moderate speed smoothly move the carriage lever to the left counter clockwise Avoid using an erratic jerking movement Once the cutter is at the tip of the key move the carriage to the right by moving the carriage lever clockwise This will result in a second cutting pass over the key blank STOP before cutter contact with the shoulder of the blank occurs 7 Press the off on switch to the off position and remove finished key by pushing down on the carriage handle until the trigger clicks into place Then loosen wing nut to remove duplicate key 8 To deburr the key turn the machine on and position the cut key lightly against
21. the rotating deburring brush Replacing the cutter The CU20 cutter used on this machine is 2 in diameter 250 thick 4 and has a Y hole It s a milling cutter made out of high speed steel It has a flat left side which is excellent for making deep cuts when these cuts are next to the shoulder such as on GM Chicago etc No warranty is placed on the cutter operators should treat it with care and avoid harsh usage Do not force the carriage up causing the key blank to bang into the cutter and do not apply heavy pressure when cutting Also do not let the cutter cut into the vise jaw this will dull the cutter quickly As with any metal cutting instrument the CU20 will dull with usage There are three ways to tell when a cutter is dull and requires replacing 1 Time a dull cutter takes longer to make the cuts 2 Sound a dull cutter will emit a shrill sound as it runs across the key blank 3 Burrs a dull cutter will not cut away the metal but will roll it away When this occurs there will be a buildup of metal burrs on the underside of the key If this buildup is heavy the cutter is dull A sharp cutter leaves little or no burrs To replace cutter use two wrenches one wrench for cutter nut and one wrench for cutter shaft Set the two wrenches in position and loosen the cutter nut Note that the cutter nut has a reverse thread and turns down ward to loosen Remove the spacer washer and the dull cutt
22. ure of handle placement Test keys A series of cut keys are supplied with your machine These keys were cut on your machine and represent the result of our quality inspectors work before approving your machine for shipment The keys are reproductions of factory dimensioned pattern keys and are accurate to 002 or less Save these keys and use them as standards to check the accuracy of cuts in the keys you make By measuring across the cuts with a micrometer you ll be able to see if your machine is cutting too deep or too shallow thus indicating that an adjustment of the cutter guide is necessary Proper key cutting techniques Even though your 024B key machine is designed to make key cutting fast easy and accurate operator tech nique is important The actual mechanics of placing keys within the vise jaws are simple to learn but there are some basics that must be followed A properly adjusted key machine used by someone who ignores good key cutting technique will NOT produce a good key The way a person clamps a key into the vise jaws is critical to the accuracy of the duplicated key Remember the real purpose of a duplicate key is to operate the lock for which it was intended If customers retum keys you should reexamine your cutting tech niques and adjustment of the machine Here are some important operating tips 1 Vise jaws clean them regularly so that no metal chips lie under the keys It is essential that both keys
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