2749A-046 Manual
Contents
1. INSTRUCTION MANUAL IMPORTANT Read these instructions before you use your new 046 Key Machine Ensure that all safety recommendations are followed See page 3 for instructions OS pr ORMANCE CUCI 1 TT This manual applies specifically to the 046 Performance Series key machine 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 If ownership of this machine is transferred this service manual should accompany the machine When seeking service information about this machine refer to M odel No 046 and the part number desired see pages 6 to 8 Note that many parts are not interchange able with other ILCO UNICAN machines CONTENTS Waranty ee Safety information Introduction unpacking Operating parts illustrated Operating parts identification names and part numbers 5 Exploded VIEW a een 6 Exploded view parts list unpacking test keys 8 How to duplicate keys srini aaa 9 The cutting operation replacing the cutter scce 12 Adj stments e seen ee 13 ONE YEAR LIMITED WARRANTY ILCO UNICAN warrants to the original buyer of any new model 046 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 arising from the faulty manufacture of the machine or from2. INTRODUCTION UNPACKING Congratulations You ve purchased a superior key cutting machine The M odel 046 manual Performance Series key machine you ve just purchased incorporates the latest improve ments in design for key duplicating machines of its type This machine features exclusive four way vise jaws designed to accommodate flat type keys safe deposit locker etc without the need for adapters Even corrugated flat keys can be duplicated with ease the four way jaws include stations ideally suited to grip ping these keys and is capable of gripping them in the groove or milling for enhanced clamping performance when necessary Accurate easy to operate and maintain the model 046 delivers excellent performance at an economical price Unpacking instructions Your 046 key machine has been shipped to you in a stur dy specially cushioned container to prevent the possibil ity of damage during handling and shipment Once the machine is removed from the carton it should be set up on a level workbench and wiped free of all rustproofing 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 046 has been engineered to duplicate flat safe deposit etc keys It is not intended or designed for any other purpose The machine opera
3. 3L 180 181 024B 181 Key Gauge Spacer Left 49 046 49 Cutter guide stylus 182 024B 182 Key Gauge Spacer Right 50 040 50 Carriage stop 183 040 183 1 4 20 Lockwasher 51 026 51 Cutter shaft thrust washer thin 184 040 184 1 4 20 Hex Nut 52 040 52 Socket hd screw 8 32 x 1 1 2 186 045 186 6 32 x 3 8 set screw 53 045 53A Cutter guide binding washer 187 045 187 dowel 54 045 54 Cutter guide binding screw 188 045 188 dowel spring 55A 045 55A Adjusting screw 189 045 189 Adjustment dial 56 040 56 Key gauge 190 045 190 Cutter guide label 57 024B 57 Key gauge bracket 194 045 194 10 flat washer 58 024B 58 Key gauge dowel pin 195 045 195 10 32 x 1 2 Button hd screw 61 025 61 Circuit Breaker ETA 1658 IM 046 IM Instruction manual 62A 025 62A On Off switch NS 025 240 220V 4HP motor 65 045 65 Machined base 68 040 68 Electrical cover 70 040 70 Rubber mount 74 040 74 Truss head screw 8 32 00 HOW TO DUPLICATE KEYS Unpacking The 046 key machine is shipped completely assembled except for the carriage handle Upon unpacking the machine locate the carriage handle and thread it into the carriage 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 dimen si
4. defective material or compo nents during a period of one 1 year from the date of shipment of the machine by ILCO UNICAN pro vided that the machine is returned by prepaid trans port to ILCO UNICAN or to its authorized representative before the expiry of the warranty peri od 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 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 buyer s 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 component thereof is warranted irrespective of w
5. of moving parts is important An oil cup is pro vided 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 lubri cation procedures should be performed every 2 3 weeks depending on usage The motor requires lubrication on an annual basis See motor label for details 15 16 I lt LMU USA ILCO UNICAN CORP 400 Jeffreys Rd Rocky Mount NC 27802 2627 Tel 252 446 3321 252 446 4702 Canada and international ILCO UNICAN INC 7301 Decarie Blvd Montreal Quebec H4P 2G7 Tel 514 735 5411 514 735 4704 Export Fax 514 735 1393 Printed in USA 125009
6. PLODED VIEW PARTS LIST Refer to pages 6 7 for illustration Ref Part no Description Ref Part no Description 1 024B 1 Carriage 13 040 75 Motor Yhp 115V 1X 024B 1X Carriage assembly 79 024B 79 Key gauge spring 2 025 2 Carriage stud 82 025 82 oll cup 3X 025 3X Vise jaw assembly 84 0248 84 Clip 4 025 4 Vise jaw spring 86X 046 86X Safety hood assembly 6X 025 6X Thrust bearing set 87 045 87 Safety shield 8 025 8 Wing nut 89 046 89 10 Lockwasher 9X 040 9X Carriage handle 90 025 90 Nut 10 32 20 025 20 Cutter shaft bushing 91 024B 91 Power cord 21 025 21 Carriage shaft bushing 92 024B 92 3 wire motor cable 23 045 23 Carriage shaft 101 1025 101 M otor pulley set screw 32 024B 32 Button head screw 10 24 x 106 040 106 Chip tray 36 025 36 Cutter nut N 4 109 025 109 Bearing washer 37 025 37 Cutter spacer 110 025 110 Wave washer 38 P SM S45 P SMS45 cutter 129 040 129 Locking nut 8 32 40A 025 40A Cutter shaft 146 040 146 Power cord strain relief 41 025 41 Cutter shaft pulley 150 040 150 Switch screw 6 32 x 1 4 43 814 00 51 Nylon brush 151 040 151 Set screw 8 32 x 3 8 45 024 45 Brush bolt washer 160 025 160 Caution label 46A 025 46A Hex head screw 18 x 163 045 163 Hood Screw 47 025 47 Motor pulley 2 3L 171 025 171 Cutter pulley set screw 18 48 025 48 V Belt
7. aced retrace the cuts by guiding the carriage to the right This will clear away any metal not removed during the initial pass over the key blank 9 Press the off on switch to the off position Remove the blank key Press the switch to the on position and remove any burrs that remain by contacting the key lightly against the deburring brush Return the switch to the off position 10 Operating Tips When duplicating a key avoid an irregular jerking motion in the movement of the car riage Acquire a smooth steady motion using both hands on the carriage to guide it Apply the same degree of pressure each time a key is duplicated Excessive pressure may cause over cutting It is sometimes best to practice on a few keys until the operator learns to impart a steady uniform pressure to the carriage Figure 5 12 Replacing the Cutter The P 455M S cutter used on this machine is 2 in diam eter 045 thick and has a hole It s a side milling slot ter made out of high speed steel 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 run into the vise jaw this will dull the cutter quickly As with any metal cutting instrument the P 455MS will dull with usage There are three ways to tell
8. e 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 dupli cated 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 Lubrication of moving parts is important An oil cup is provided to keep the cutter shaft bearings well lubricat ed 5 7 drops of 3 in 1or 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 per formed every 2 3 weeks depending on usage The motor requires lubrication on an annual basis See motor label for details w HOW TO DUPLICATE KEYS General key duplication procedures WARNING Do not install or remove keys unless the offfon switch is in the OFF position Always wear eye protection when operating this machine There are f
9. hether 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 rea son other than a breach of its warranties hereunder The liability ofILCO UNICAN shall in no case includ ing negligence exceed the purchase price of the defec tive machine nor shall ILCO UNICAN be liable for any personal injuries property damage or consequen tial 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 Operator s M anual for informa tion on how to properly operate it The likelihood of acci dents 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 subject to potential injury from flyi
10. ion for your store as a good place to have keys duplicated 13 ADJUSTMENTS Adjusting for spacing There is no adjustment for spacing However if a key gauge assembly is ever replace the 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 Adjust 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 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 busi ness card Do not allow a greater distance since this many 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 peri odically with a lightly oiled cloth We suggest brushing the jaws often as even a single filing can alter the accu racy of the machine Lubrication Intervals Lubricating
11. ng 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 for bidden Electrical safety 115 Volt models Your machine is designed to oper ate 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 ground ing provides a path of least resistance for electric cur rent to reduce the risk of electric shock This machine is equipped with an electric cord that has an equip ment 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 operator should take care to e
12. nsure 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 Operator s 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 equip ment 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 damaged or worn cords immediately uy
13. o the left of the vise jaw s left edge Holding the key blank firmly and level against the jaw tighten the wing nut Position the pattern key in the car riage s LEFT vise jaw in a similar manner only this time allowing a gap between the shoulder of the key and the edge of the vise jaw Next lower the key gauge and position the carriage so that the left edge of the gauge s RIGHT prong contacts the edge of the key blank s shoulder see Figure 3 Loosen the wing nut securing the pattern key and repo sition the key so that its shoulder is in contact with the Figure 3 Fea Vert nt Fa A ii Mili AA th r a ma A AA left edge of the LEFT prong of the key gauge Check to ensure that the pattern key and blank key s shoulders are snug against the key gauge and both keys are positioned level not tilted in the vise jaws Retighten the wing nut Aligning keys in the vise jaws Keys without shoulders Most flat keys do not have a conventional shoulder With such keys the aligning point is generally the verti cal surface closest to the tip of the key see Figure 4 End Stop To align these keys clamp the blank key in the RIGHT vise jaw and move the machine carriage to the left Lower the key gauge and position the carriage so that the key gauge prong contacts the vertical surface indicated in Figure 4 Insert and align the pattern key in the left vise jaw in the same manner Figure 4 Use of gauge with va
14. oned pattern keys and are accurate to 002 or less You can conduct periodic testing of your machine s accuracy by uplicating a key and then using a key micrometer or caliper to compare the actual depth of the cuts on both the dupli cate and the pattern key will allow you 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 046 key machine is designed to make key cutting fast efficient and accurate operator skill is important The actual mechanics of placing keys within the vise jaws is 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 tech niques 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 return 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 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 fre
15. our procedures that the machine operator per forms 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 duplicat ed to 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 duplicat ed See U sing the four way vise jaws section 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 WwW gt Using the four way vise jaws Your 046 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 flat style key see Fig 1 Figure 1 STANDARD Rotate both jaws as a set 10 Using the four way vise jaws cont To obtain the best gripping action possible it is neces sary to assure that the proper vise jaw position is select ed for each key you duplicate The vise positions are explained below and proper usage shown in figure 2 Standard for holding most typical flat keys including many common safe deposit locker and corrugated pad lock types Narrow for holding narro
16. rious key types Fa krp Cerar z A Shoulder Stop A Recessed tip It is important that the key gauge prongs are in contact with both keys at the same time 11 HE 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 1 Rotate both vise jaws to the station suitable for the key being duplicated Insert the blank key and pattern key into the vise jaws 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 tilt ed Lower the key gauge to align the keys using an appropriate method as described under Aligning Keys found in the previous section see page 10 After the keys are aligned return the gauge to its up position gt W gt I Press the off on switch to the on position 6 Lift the carriage with both hands see Figure 5 7 Move the carriage to line up the cut ter guide with the shoulder of the pattern key then shift slightly away from the shoulder Do not permit the cutter to touch the shoulder of the key blank 8 Press in on the carriage while guiding it to the left Carefully trace the cuts of the pattern key with the cutter guide The cutter will make a corresponding cut in the key blank When the cut closest to the tip of the pattern key has been tr
17. s 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 rota tion of the cutter before changing adjustment There will Figure 7 Binding Depth Adjustment Dial Carriage stop adjusting screw ADJUSTMENTS 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 ad justment To adjust the cutter guide loosen the binding screw on top of the cutter guide slightly see Fig 7 amp 8 Once you have loosened this screw the depth Depth A Dial Figure 8 Binding Plate adjustment dial can be Binding rotated to the left to Screw decrease depth of cut or to the right to increase depth of cut Again proper adjustment will be achieved when the cutter just barely grazes the key blank before it while the cut ter guide is in contact with the other key blank Retighten the binding screw once the calibration process is com pleted Recheck after tightening to assure that adjust ment did not shift Carriage Stop Each calibration mark on the depth adjustment dial is equi
18. tor 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 pro tective eye glasses or goggles when operating this ma CAUTION chine 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 un loading 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 SPECIAL SHIPPING CARTON STORE IT CAREFULLY IN A SAFE PLACE THIS CARTON SHOULD BE USED WHENEVER THE MACHINE IS MOVED OR SHIPPED OPERATING PARTS Safety hood assembly Cutter guide Key gauge Carriage shaft Operating parts identification Part no Identification 024B 1 Carriage 025 3X Vise jaw assembly 025 8 Wing nut 045 23 Carriage shaft P SM S45 P SM S45 cutter 814 00 51 Nylon brush 046 49 Cutter guide stylus 045 55A Adjusting screw 040 56 Key gauge 025 62A On Off switch 025 82 Oil cup 046 86X Safety hood assembly 045 87 Safety shield Vise jaw assembly Safety shield Carriage On Off power switch EXPLODED VIEW EXPLODED VIEW EX
19. valent to approx 0015 1 1 2 thousandths of an inch As you can see this system can allow for very pre cise adjustment of your new key machine In fact if you have a key micrometer or dial caliper available you can adjust your machine with factory accuracy To do this you would simply duplicate a key and measure cuts on both the pattern key and the duplicate key for com parison This would show any deviation that existed and whether the duplicate cuts were too deep or too shallow and by how much With this information you can use the depth adjustment dial on your machine to calibrate your machine for best possible accuracy This is very important as many locks are designed with close fit tol erances and the keys you duplicate are often themselves copies functional but just barely so The more accurate your key machine is adjusted the closer your duplicates will match their originals resulting in fewer non func tional miscuts It is very important to understand that adjusting your machine is not a one time procedure As the cutter on your machine wears down the machine must be adjust ed to compensate It is good shop practice to check your machines depth adjustment every 2 4 weeks based upon your store s key cutting volume and readjust as necessary You will find that re calibration is seldom needed but by checking and correcting BEFORE cus tomers begin returning miscut keys you will create a rep utat
20. w flat keys as well as those with very deep cuts Wide for holding wide flat keys typically those 1 2 or more in width X sometimes quite useful for holding corrugated flat keys and those with milled grooves Generally if such keys cannot be securely gripped using another vise posi tion this position may provide improved clamping per formance Using standard position Using wide position Arm Using X position Using narrow position To reposition the vise jaws as from Standard to Wide 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 rotat ed to the same position HOW TO DUPLICATE KEYS 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 properly aligned and securely clamped in the vise jaws To do this slide the machine s carriage assembly towards the right and position the appropriate key blank in the carriage s RIGHT vise jaw with the head of the blank pointing to the left Ensure that the shoulder of the key blank is located approximately t
21. when a cut ter 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 the cutter use two wrenches one wrench for the cutter nut and one wrench for the cutter shaft Set the two wrenches in position and loosen the cutter nut Note that the cutter nut has a reverse thread and turns downward to loosen Remove the spacer washers and the dull cutter Install the new cutter the washers and the nut 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 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 6 Figure 6 Adjustment is correct when both key blanks touch To check the depth adjustment insert two identical key blanks into the vise jaws setting them flat in each vise It i
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