Silca DUO POWER Operating Manual

This manual has been drawn up by SILCA S.p.A. All rights reserved. No part of this publication may be reproduced or used in any form or by any means (photocopying, microfilm or other) without the written permission of SILCA S.p.A. Edition: october 2010 Printed in India by MINDA SILCA Engineering Ltd. Plot no.37, Toy City, GREATER NOIDA (U.P.) - 201308 IMPORTANT NOTE: in compliance with current regulations relating to industrial property, we hereby state that the trade-marks or trade names mentioned in our documentation are the exclusive property of authorized manufacturers of locks and users. Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our keys are made can be rapidly identified.

1.3 Unpacking .............................................................................................5 1.4 Handling the machine ...........................................................................5 2 DUO / DUO POWER machines WORKING PARTS ......................................6 3 DUO BRAZIL machine WORKING PARTS ...................................................7 4 MACHINE DESCRIPTION ...............................................................................8 4.1 Technical Data ......................................................................................9 4.2 Graphics . ..............................................................................................9 4.3 Electric circuit ......................................................................................10 5 ACCESSORIES PROVIDED .........................................................................11 6 MACHINE INSTALLATION and PREPARATION ........................................12 6.1 Checking for damage ..........................................................................12 6.2 Environmental conditions ....................................................................12 6.3 Positioning . .........................................................................................12 6.4 Description of work station ..................................................................13 6.5 Separate parts ....................................................................................13 6.6 Connection to the mains .....................................................................13 6.7 Cutter shield ........................................................................................14 7 MACHINE REGULATION AND UTILIZATION .............................................15 7.1 Checking and setting ..........................................................................15 7.2 Calibration - LEFT-HAND CARRIAGE ...............................................15 7.3 Calibration - RIGHT-HAND CARRIAGE .............................................17 8 CUTTING OPERATIONS ..............................................................................20 8.1 Key cutting ..........................................................................................20 8.1.1 Carriage release (right or left-hand side) .............................................20 8.1.2 Clamp rotation .....................................................................................20 8.1.3 Carriage translation on DUO key-cutting machine ..............................21 8.1.4 Carriage translation on DUO BRAZIL key-cutting machine .................21 8.1.5 Flared cuts cutting bit keys (right-hand carriage) .................................22 8.2 Cutting flat cylinder and vehicle keys - LEFT-HAND carriage ............23 8.2.1 Using the accessories ..........................................................................25 8.3 Cutting double bit, pump and mail box keys - RIGHT-H. carriage.......27 8.3.1 Cutting bit and double bit keys .............................................................29 8.3.2 Cutting keys with central stop ..............................................................30 8.3.3 Cutting mail box keys ...........................................................................30 8.3.4 Cutting pump keys ...............................................................................31 9 MAINTENANCE .............................................................................................33 9.1 Replacing the cutting tool ...................................................................33 9.2 Access to the lower part .....................................................................34 9.3 Replacing the brush ............................................................................35 9.4 Replacing and/or tightening the belt ...................................................35 9.5 Replacing the tracer point ...................................................................36 9.6 Regulating left carriage depth .............................................................37 9.7 Replacing the fuses ............................................................................37 9.8 Replacing main switch ........................................................................38 9.9 Replacing motor on switch ..................................................................39 9.10 Replacing motor/condenser ................................................................40 9.11 Replacing lamp ...................................................................................41 10 DISPOSAL ....................................................................................................42 11 ASSISTANCE ................................................................................................43 11.1 How to request service .......................................................................43

DUO Copyright Silca 2 010 3 GUIDE TO THE MANUAL This manual has been produced to serve as a guide for users of the DUO key-cutting machine. Read it carefully; it is essential if you wish to operate your machine safely and efficiently. Consultation The contents of the manual are divided into sections relating to: - Transport and handling ....................................................................................... Ch. 1 - Description of machine and safety devices ........................................................ Ch. 2-3-4-5 - Proper use of machine ........................................................................................ Ch. 6-7-8 - Maintenance ........................................................................................................ Ch. 9 Technical terms Common technical terms are used in this manual. To assist those with little experience of key cutting, below is an illustration of the terms used for the different parts of keys: Fig. 1 Fig. 2 1) Head 2) Rim 3) Stop 4) Blade 5) Tip 6) Back 7) Cuts 8) Stem 9) Bit 1 1 1 3 3 3 7 7 8 2 2 5 5 5 4 6 WITH LEFT-HAND CARRIAGE only on DUO BRAZIL version 1 8 3 5 7 8 9 WITH RIGHT-HAND CARRIAGE PUMP KEYS ATTENTION: see chap. 8.3.4. ONLY on DUO POWER version ONLY on DUO and DUO BRAZIL

4 Copyright Silca 2 010 GENERAL INTRODUCTIONS The DUO key-cutting machine has been designed according to the specifications of the Machine Direc- tives. From the design stage risks for the operator have been eliminated in all areas: transport, key-cut- ting, regulation and maintenance. Other risks have been eliminated by the use of protective devices for the operator. The protective devices used are designed not to provoke further risks and, above all, they cannot be ignored unless deliberately cut out. They do not hinder visibility of the work area. A special adhesive label is attached to the machine warning the operator to use goggles during the cut- ting operations, and this is strongly recommended in this manual. The material used in the manufacture of this machine and the components employed during use of the machine are not dangerous and their use complies with standards. Use The DUO must be installed and used in the way laid down by the manufacturer. If the key-cutting machine is used differently or for purposes differ ent from those describe d in this manual, the customer will forego any rights he may have over SILCA S.p.A. Furthermore, unforeseen danger to the operator or any third parties may arise from incorrect use of the machine. Negligence in the use of the machine or failure on the part of the operator to observe the instructions given in this manual are not covered by the guarantee and the manufacturer declines all responsibility in such cases. It is therefore indispensable to read the operating manual carefully in order to make the best use of the DUO and benefit from its potential. Instructions manual The instructions manual provided with the machine is essential to its proper use and to carry out th e necessary maintenance. We therefore recommend protecting the manual from damage in a safe sheltered place, easily to hand for quick consultation. Further Risks There are no further risks arising from the use of the machine. Protection and safety precautions for the operator The DUO key-cutting machine is built entirely to standards. The operations for which it has been de- signed are easily carried out at no risk to the operator. The adoption of general safety precautions (wearing protective goggles) and observation of the instruc- tions provided by the manufacturer in this manual eliminate all human error, unless deliberate. The DUO key-cutting machine is designed with features which make it completely safe in all its parts. • Power supply The key-cutting machine is powered by electricity supplied through a separable earthed plug. • Start-up The machine is started up: - activating the safety main switch on the left-hand side of the machine; - activating the motor on switch the left-hand side. • Maintenance The operations to regulate, service, repair and clean the machine have been devised in the simplest and safest way possible. There is no danger of removable parts being re-placed wrongly or unsafely. • Machine Identification The DUO key-cutting machine is provided with an identification label which shows the serial number (fig. 3). Fig. 3 (*) see chap. 10 "DISPOSAL", page 42.

DUO Copyright Silca 2 010 5 1 TRANSPORT The DUO key-cutting machine is easily transported and is not dangerous to handle. The packed ma- chine can be carried by one person. 1.1 Packing The DUO is packed in a strong cardboard box, the dimensions of which are shown in fig. 4, sufficiently robust to be used for storing the machine for long periods. Inside the box the machine is enclosed in two expanded polymer shells. The shells and cardboard box ensure safe transportation and protect the machine and all its parts. Fig. 4 1.2 Transport To avoid damaging the DUO it must always be transported in its packing case. This will prevent sudden movements or rough handling from damaging the machine, persons or things. 1.3 Unpacking To remove the machine from the packing box: 1) cut the straps with scissors and remove, 2) prise off the staples, 3) open the box without damaging it as it may be used again (e.g. removals, dispatch to the manufac- turers for repairs or servicing), 4) check the contents of the box, which should comprise: - 1 DUO key-cutting machine packed in a protective shell; - 1 set of documents, including: operating manual, spare parts list and guarantee; - 1 connecting wire; - 1 tool kit 5) remove the key-cutting machine from the protective shell. 1.4 Handling the machine When the DUO has been unpacked, place it directly on its workbench. This operation can be carried out by one person, firmly holding the base, and no other part, to lift and carry the machine. 500 596 350 Keep dry This side up Handle with care

6 Copyright Silca 2 010 2 DUO / DUO POWER machines WORKING PARTS Fig. 5 A - left-hand carriage A1 - carriage lock/release pin - left-hand side B - right-hand carriage B1 - carriage lock/release pin - right-hand side C - left-hand carriage movement lever D - clamps for flat keys D1 - gauges knob E - clamps knobs (left-hand carriage) F - prismatic cutter for flat keys G - left tracer point for flat keys G1 - centesimal ring - left tracer point H - right-hand carriage movement lever J - clamps for bit keys K - clamps knobs (right-hand carriage) L - tilting movement activating pin (right-hand car- riage) M - milling cutter for bit keys N - right tracer point for bit keys N1 - centesimal ring - right tracer point O - handwheel for carriage movement P - brush Q - top cover R - lamps S - chippings tray T - main switch U - motor on switch V - supply socket V1 - fuses W - cutters protective shield A B C D E H A1 B1 J J K K O L N G G1 N1 F M P Q R S W R DUO / DUO POWER T V U D1 V1

DUO Copyright Silca 2 010 7 3 DUO BRAZIL machine WORKING PARTS Fig. 6 A - left-hand carriage B - right-hand carriage C - left-hand carriage movement lever D - clamps for flat keys D1 - gauges knob E - clamps knobs (left-hand carriage) F - prismatic cutter for flat keys G - left tracer point for flat keys G1 - centesimal ring - left tracer point H - right-hand carriage movement lever J - clamps for bit keys K - clamps knobs (right-hand carriage) L - tilting movement activating pin (right-hand car- riage) M - milling cutter for bit keys N - right tracer point for bit keys N1 - centesimal ring - right tracer point P - brush Q - top cover R - lamps S - chippings tray T - main switch U - motor on switch V - supply socket V1 - fuses W - cutters protective shield A B C D E H J J K K L N G G1 N1 F M P Q R S W R DUO BRAZIL T V U D1 V1

8 Copyright Silca 2 010 4 MACHINE DESCRIPTION DUO is a professional key-cutting machine, designed to duplicate: • flat keys for cylinders and vehicles and cruciform keys: with left-hand carriage. • bit, double bit, pump and mail box keys*: with right-hand carriage. Fig. 7 The main parts of the machine are described below: Main switch The key-cutting machine is co nnected to a power supply socket provided with a differential switch. Pressing the switch (T) powers the machine and illuminates the lamps (R) to indicate that current is on. ATTENTION: Switch (T) is electromagnetic, in the event of a power failure it goes out automatically. When electricity is restored it must be reset manually to power the machine again. Motor on switch On the left-hand side of the DUO key-cutting machine there is also a switch for starting up the motor (U). ATTENTION: the illuminated switch remains on to indicate that the key-cutting machine has been started (cutter in motion). Motor and transmission unit Motor transmission takes place by belt. On the right-hand side of the motor there is the transmission shaft which moves the brush (P). On the left-hand side of the motor there is the shaft which moves the cutter spindle. These components are protected by a top cover (Q). Clamp carriages The carriages comprise two clamps. They move horizontally and frontally controlled by handles (C and H). The DUO machine carriages can be locked into a fixed position and in this way achieve translation by means of the flywheel located on the right-hand side of the machine (chap.8.1.3, page 21) (Attention: not available on Duo Brazil version). The carriages are so designed as to avoid accumulation of dust or cutting swarf. The machine is designed with a ramp along which chippings can fall into the special chippings tray (S) placed under the carriage and easily removable for emptying and cleaning. Cutting unit The cutting unit contains the actual working parts of the DUO key-cutting machine, which operate to- gether to cut and finish keys "read" from the originals. The working parts are described below: • Cutting Tools The cutting tools (F) and (M) are the parts of the DUO used for cutting key blanks. The cutting tools are in HSS super rapid steel and are protected by a special cover (W) to ensure safe operation. The shield (W) is mobile and can be placed over the cutter that is not in use. • Tracer points The tracer points are dedicated to reading cuts on the key to be duplicated and are: - tracer point (G) on the left-hand side of the machine, for flat keys for cylinders and vehicles and cru- ciform keys; - tracer point (N) on the right-hand side of the machine, for bit, double bit, pump and mail box keys*. The depth of the tracer points is easily regulated by means of the relative graduated nut. * Mail box keys only on DUO and DUO BRAZIL versions DUO / DUO POWER DUO BRAZIL

DUO Copyright Silca 2 010 9 • Clamps Left-hand carriage The clamps (D) are rotating and four-sided to allow perfect closure of the key placed on its back or profile in the case of keys with symmetrical cuts (chap.8.2, page 23). Right-hand carriage The clamps (J) are rotating, two/three sided to allow perfect closure of bit, double bit, pump and mail box keys* (chap.8.3, page 27). • Clamps knobs The clamps are locked by two anatomical knobs (E) or (K), which ensure perfect grip on the keys with only slight locking pressure. • Calibration tabs The clamps have two gauge tabs (left-hand carriage) with which to adjust key alignment. • Brush The brush (P) is used to eliminate burrs from the cuts and is made of non-abrasive material. 4.1 Technical Data ELECTRICAL PROPERTIES: - 230V-50Hz 300W 1,2A - 120V-60Hz 250W 2,3A CUTTING TOOLS: HSS Super Rapid Steel MOTOR: One-speed single phase - 230V-50Hz (1400 rpm) - 120V-60Hz (1700 rpm) MOVEMENTS: by gear on rectified carriage CLAMPS: rotating 4 sides (left carriage), 2/3 sides (right carriage) MAXIMUM LENGTH OF CUTS: - flat cylinder keys: 42 mm - bit and double bit keys: 25 mm DIMENSIONS: width: 510 mm - depth: 450 mm - height: 280 mm SONOROUS PRESSURE: Leq. = less than 70 dbA WEIGHT: Kg.23 4.2 Graphics * Mail box keys only on DUO and DUO BRAZIL versions THE USE OF PROTECTIVE GOGGLES IS COMPULSORY

10 Copyright Silca 2 010 4.3 Electric circuit The main parts of the electric circuit on the DUO are listed below: 1) Main socket with fuses 2) Safety main switch 3) Illuminated switch 4) Motor: 230V- 50Hz (120V-60Hz) 5) Condenser 6) Lamps 2 3 4 1 blue blue brown brown blue brown brown blue yellow/green 1 2 3 4 5 6

DUO Copyright Silca 2 010 11 5 ACCESSORIES PROVIDED it is advisable to always have certain spare parts on hand. It is advisable to always have a tool box con- taining: tools, cutting tools, brushes, belts and small replacement parts. DUO is supplied with a full range of accessories. The accessories provided by Silca are all that is nec- essary to carry out the operations for which the machine is designed. STEEL PIN Ø 1,20 2 pcs STEEL PIN Ø 1,70 2 pcs FUSES 5X20 (2 pcs) 4 Amps rapid (230V) 8 Amps rapid (120V) 2,5 mm ALLEN KEY 3 mm ALLEN KEY 19 mm SPANNER CUTTING TOOL UNCLAMPING PIN ADJUSTING BAR 2 pcs 4 mm ALLEN KEY 5 mm ALLEN KEY STEEL BAR 2 pcs CLEANING BRUSH ADJUSTING PINS 2 pcs

12 Copyright Silca 2 010 6 MACHINE INSTALLATION AND PREPARATION The DUO key-cutting machine can be installed by the purchaser and does not require any special skills. However, some checks and preparation for use need to be carried out by the operator. 6.1 Checking for damage The DUO key-cutting machine is solid and compact and will not normally damage if transport, unpacking and installation have all been carried out according to the instructions in this manual. However, it is always advisable to check that the machine has not suffered any damage. 6.2 Environmental conditions To ensure that the best use is made of the DUO key-cutting machine, certain parameters must be borne in mind: - damp, badly ventilated sites should be avoided. - The ideal conditions for the machine are: - temperature: from 10 to 40°C - relative humidity: approx. 60% 6.3 Positioning Place the key-cutting machine on a horizontal surface, solid enough to take the weight (23 Kg). To facilitate operation and maintenance, install the machine with a space of at least 200 mm on all sides (fig. 8). Ensure that the machine stands perfectly balanced on the four feet. Vibration is avoided when the ma- chine is properly set on the horizontal plane. ATTENTION: ensure that the machine voltage is the same as that of the mains, which must be properly earthed and provided with a differential switch. Fig. 8 200 mm 200 mm 200 mm

DUO Copyright Silca 2 010 13 6.4 Description of work station The key-cutting machine needs only one operator, who has the following controls at his/her disposal: - Main switch (T), located on the left-hand side of the machine, it activates the machine and turn on the lamps (R). - Motor on switch (U), located on the left-hand side of the machine has a warning light to show that the key-cutting machine is live. Left-hand carriage: - Carriage lever (C) - Carriage release pin (A1) (not available on Duo Brazil version) - Gauges knob (D1) - Carriage advancement flywheel (O) (with carriage locked - chap. 8.1.3, page 21) (not available on Duo Brazil version). Right-hand carriage: - Carriage lever (H) - Carriage release pin (B1) (not available on Duo Brazil version) - Carriage advancement flywheel (O) (with carriage locked - chap. 8.1.3, page 21) (not available on Duo Brazil version). - Tilting movement activating pin (L) Fig. 9 (*) not available on Duo Brazil version 6.5 Separate parts The separately packed parts must be installed on the DUO key-cutting machine by the purchaser, as follows: Connection wire Connect the key-cutting machine power cable to the electricity mains (fig. 10). Fig. 10 6.6 Connection to the mains For the safety of the operator and the machine it is important to ensure that the machine is connected to the proper mains voltage by means of an earthed differential switch. T U H C A1 B1 O D1 L * * * R R power cable electricity supply

14 Copyright Silca 2 010 6.7 Cutter shield The shield (W) is mobile and can be placed over the cutter when not in use: - to operate the left-hand carriage, take shield (W) to the right (fig. 11) - to operate the right-hand carriage, take shield (W) to the left (fig. 12) Fig. 11 Fig. 12 W W

DUO Copyright Silca 2 010 15 7 MACHINE REGULATION AND UTILIZATION 7.1 Checking and setting The cutting tools on the DUO are the parts used to cut the key blanks and should be periodically checked and replaced, if necessary. Every time the cutting tool is changed, and during periodical operational tests, check calibration. 7.2 Calibration - LEFT-HAND CARRIAGE The DUO key-cutting machine requires two types of calibration: axis and depth. Axis calibration: Axis calibration is regulation of the space between the stop and the cuts (fig. 13). The axis setting is fixed and is established on assembly in our workshops. Fig. 13 Depth calibration: Depth calibration is regulation of the cutting depth (fig. 13-A). Proceed as follows: 1) Ensure that the key-cutting machine is off by unplugging the power cable. 2) Place the adjusting keys (provided) on the clamps (fig. 13-B). 3) Check that the adjusting keys adhere properly to the clamps. 4) Turn the gauge rod (D2) towards the operator so that the gauges come into contact with the adjusting keys (fig. 14). Lower the gauge rod. Fig. 14 5) Release the carriage by raising the release lever. 6) Raise the carriage and take up to the cutting tool (fig. 15). 7) Turn the cutting tool anticlockwise manually and check that it skims the adjusting keys in several plac- es. 8) If necessary, regulate the depth of the cut with the micrometric tracer point, as follows: a) loosen the screw (G2) holding the tracer point. b) turn the ring nut (G1) clockwise to advance the tracer point (fig. 15 and fig. 16). c) turn the ring nut (G1) anticlockwise to return (fig. 17). B 6 4 8 9 0 cutting I II III IV V VI cutting space depth A

16 Copyright Silca 2 010 ATTENTION: each notch on the centesimal ring corresponds to 0,025 mm (fig. 15-A). 9) Repeat these operations until regulation is complete, then tighten the tracer point locking grub screw (G2). Fig. 15 Fig. 16 Turn the nut to the RIGHT (clockwise) to take the tracer point down. Result: LESS DEEP CUTS Fig. 17 Turn the nut to the LEFT (anticlockwise) to take the tracer point up. Result: DEEPER CUTS 0,025 mm 0,1 mm A G1 B G2 cutting tool G1 G2 cutting tool G1 G2

DUO Copyright Silca 2 010 17 7.3 Calibration - RIGHT-HAND CARRIAGE Axis calibration Axial gauging is regulation of the spaces for the cuts on the key (fig. 18). Fig. 18 Axis gauging control 1) Turn off the machine and unplug the power lead. 2) Make sure the tracer point and cutter are of the same thickness. 3) Lock the tilting movement of the clamps by inserting the pin (L) into its seat. 4) Close the 2 clamps with their knobs (K). 5) Release the carriage by turning the pin (B1) (not available on Duo Brazil version). 6) Use the lever (H) to raise the carriage and take the right-hand side of the clamp up against the left- hand side of the tracer point and cutter (fig. 19). 7) The ideal condition is for both tools (tracer point and cutter) to be in contact with the relative side of the clamp. If this is not so, loosen the 2 tracer point holder screws (N2) (fig. 19) and move the tracer point holder manually (right or left) until the ideal condition is found. 8) Tighten the 2 screws (N2). Fig. 19 cutting space cutting depth L H K K N3 B1 N2

18 Copyright Silca 2 010 Depth calibration Depth calibration is regulation of the cutting depth (fig. 18). Proceed as follows: 1) Ensure that the key-cutting machine is off by unplugging the power cable. 2a) DUO and DUO BRAZIL: place the adjusting keys on the clamps (fig. 20-a) on the 2nd side for mail box keys - fig. 38); 2b) DUO POWER: place the adjusting pins on the clamps (fig. 20-b) on the 1st side for bit/double bit keys - fig. 39). 3) Lock the clamps in the horizontal position by means of the pin (L); 4) Raise the carriage and take the adjusting keys (or pins) into contact with the tracer point and cutting tool (fig. 20). 5) Turn the cutting tool manually in the opposite sense to the rotation and check that it skims the adjust- ing key (or pin) in several places. 6) If necessary, regulate the cutting depth by means of the tracer point, as described; loosen grub screw (N3) and: - turn the ring nut (N1) clockwise to advance the tracer point (fig. 21). - turn the ring nut (N1) anticlockwise to return (fig. 22). 7) Repeat these operations until the cutting tool skims the adjusting key (or pin) in several points. Fig. 20 cutting tool N1 N3 N1 N3 a) DUO / DUO BRAZIL b) DUO POWER

DUO Copyright Silca 2 010 19 Fig. 21 Turn the nut to the RIGHT (clockwise) to take the tracer point down. Result: LESS DEEP CUTS. Fig. 22 Turn the nut to the LEFT (anticlockwise) to take the tracer point up. Result: DEEPER CUTS. cutting tool N1 cutting tool N1

20 Copyright Silca 2 010 8 CUTTING OPERATIONS ATTENTION: for complete safety during the cutting operations, take the following precautions: • Always work with dry hands. • Check that the machine is properly earthed. • Wear protective goggles even if the machine has a protective shield over the cutting tool. • Start the motor (switch U) only after completing the operations on the carriage (securing the keys, etc...). • Keep hands away from the cutting tool in motion. 8.1 Key cutting Cutting can be carried out in two ways: • with the carriage in a fixed position (locked carriage) (Attention: not available on Duo Brazil version) • with the carriage in a mobile/free position (carriage released) ATTENTION: if cutting is carried out with the carriage in a fixed position, before proceeding release the carriage not to be used (Attention: not available on Duo Brazil version). ATTENTION: if cutting is carried out with the carriage in a free position, use handle (C) or (H) to raise and move the carriage. 8.1.1 Carriage release (right or left-hand side) Attention: not available on Duo Brazil version - turn the carriage lock/release pin to the right (A1 or B1) (fig. 23). Fig. 23 The clamps must be prepared according to the type of key to be cut (fig. 24). 8.1.2 Clamp rotation 1) Loosen the clamp closing knob by a few turns. 2) Raise the clamp (both jaws) and turn so that the re- quired side is facing the tracer point and cutter. Note: carry out the operation on both clamps. Fig. 24 A1 B1 C H

DUO Copyright Silca 2 010 21 8.1.3 Carriage translation on DUO key-cutting machine • If the carriage to be used for cutting is in the fixed position (carriage locked), to move it: - take the carriage up to the tracer point and cutter by means of the handle (C or H). - turn the flywheel (O) to move the carriage sideways and carry out cutting. • If the carriage to be used for cutting is in a mobile/free position (carriage released), to move it: - use the handle (C) or (H) to both raise and move the carriage. Fig. 25 8.1.4 Carriage translation on DUO BRAZIL key-cutting machine - use the handle (C) or (H) to both raise and move the carriage. Fig. 26 DUO / DUO POWER O C H C H DUO BRAZIL

22 Copyright Silca 2 010 8.1.5 Flared cuts cutting bit keys (right-hand carriage) Tilting clamps The clamps on the right-hand carriage, used to cut bit, double bit and rim keys, may be of th e tilting type so that the cuts can be flared. • To activate tilting: pull out the pin (L). • To deactivate tilting: inser t the pin (L) to lock the clamps in the fixed horizontal position. Fig. 27 Fig. 28 Fig. 29 L L

DUO Copyright Silca 2 010 23 8.2 Cutting flat cylinder and vehicle keys - LEFT-HAND carriage Fig. 30 1) Turn the clamps to find the appropriate side for securing the key (fig. 30). 2) Loosen the knobs (E) by a couple of turns. 3) Raise the lower part of the clamps and turn to the required position (fig. 24): - Side A of the clamp: for keys to be fitted on their backs, keys with double cuts without groove and cruciform keys (fig. 30); - Side B of the clamp: for keys placed on their backs and having cuts with a depth of less than 3,9 mm (fig. 30); - Side C and D of the clamp: for keys to be cut on both sides and locked on the groove (fig. 30). D A B C D A B C DUO BRAZIL key-cutting machine DUO / DUO POWER key-cutting machine max.42 mm DUO BRAZIL only with

24 Copyright Silca 2 010 Securing the keys in the clamps 1) Position the original key (left-hand jaw) and key blank (right-hand jaw), ensuring that: a) the keys are well positioned and secured in the clamp; b) the key stop is resting against the calibration tabs (D2) (fig. 31); 2) secure the keys by closing the clamps with the knobs (E). Fig. 31 Key cutting ATTENTION: make sure the gauge rod has been lowered. When the DUO key-cutting machine has been turned on by means of switch (U) it is ready for cutting: 3) Take the carriage towards the tracer point/cutter (fig. 32). 4) Move the carriage from right to left to cut the key (see chap. 8.1.3, page 21). In case of double cuts repeat the operation in the second side of the key. 5) Turn off the machine with witch (U) before removing the duplicated key. 6) Remove the keys from the clamps. 7) Turn on the machine with switch (U) and smooth off the key edges by means of the brush (P). Fig. 32 D2 D2 E E

DUO Copyright Silca 2 010 25 8.2.1 Using the accessories The accessories provided with the DUO to assist key-cutting are: • pins • bars Using the pins The pins must be inserted between the bottom of the jaw and the back of the key for keys with narrow stems, and their purpose is to ensure that the key protrudes sufficiently to be cut properly (fig. 33-B, fig. 33-C). For keys with narrow, thin stems, two pins must be used (fig. 33-B) the second one to give a secure grip on the key. If the key thickness is too fine to guarantee a good grip in the clamps, a pin must be used (fig. 33-A). ATTENTION: the pins provided have two different diameters: 1,20 mm and 1,70 mm; It is essential to use pins with the same diameters for locking both the original and the key blank. Fig. 33 A B C pin

26 Copyright Silca 2 010 Using the bars The bars provided are used for cutting pin keys and as a tip rest for locking keys with no stop (fig. 34). Cutting cruciform keys using bars The cruciform keys (90°) can be cut with the DUO clamps and the aid of the bars. Positioning cruciform keys: 1) Leave the gauges in the idle position. 2) Insert the bars with neck into the slot in the clamps. 3) Butt the key stop against the bars. 4) Secure the keys in the clamps. 5) Remove the bars from the clamp grooves to prevent it being touched by the tracer point or cutting tool. 6) Cut the first side. 7) Repeat the operation, turning the keys in the same direction for the other positions. Fig. 34 Tip stop with a bar The bars can be used with keys which have no stop (fig. 35); proceed as follows: 1) Leave the gauges in the idle position; 2) Insert the bars into the slot in the clamps; 3) Rest the tip of the key against the bar; 4) Secure the key and remove the bar. Fig. 35 bar

DUO Copyright Silca 2 010 27 8.3 Cutting bit, double bit, pump and mail box keys* - RIGHT-HAND carriage Note: the right-hand carriage clamps cannot be interchanged; the tracer point side clamp is marked with the letter “T” (fig. 36). Fig. 36 Fig. 37 * Mail box keys only on DUO and DUO BRAZIL versions Ø min.3,5 max.7 mm max.125 mm max. max. 12 mm 15 mm min. Ø min.3,5 max.7 mm 26 mm max.30 mm max.25 mm min.26 mm depth 12 mm max PUMP KEYS: some models only The duplication is possible for keys with these characteristics. DUO and DUO BRAZIL DUO POWER The duplication is possible for keys with these characteristics. PUMP KEYS BIT and DOUBLE BIT KEYS, PUMP KEYS, MAIL BOX KEYS* ONLY on DUO and DUO BRAZIL max.7 mm max. max. 12 mm 15 mm min. Ø min.3,5 max.7 mm 14 mm max.20 mm

28 Copyright Silca 2 010 1) Turn the clamps to find the appropriate side for securing the key (fig. 38) (fig. 39). 2) Loosen the knobs (E) by a couple of turns. 3) Raise the lower part of the clamps and turn to the required position (fig. 24): Fig. 38 DUO and DUO BRAZIL - Clamp side for bit, double bit keys and bit keys with central stop (position 1) - Clamp side for pump keys with ROUND stem (position 1 turned 90°) - Clamp side for mail box keys (position 2) Fig. 39 DUO POWER - Clamp side for bit, double bit keys and bit keys with central stop (position 1) - Clamp side for pump keys (position 2 turned 90°) 180° 90° 1 2 bit and double bit keys mail box keys DUO and DUO BRAZIL 1 2 1 pump keys ROUND stem 1 2 DUO POWER 1 2 90° pump keys bit and double bit keys 2 pump keys

DUO Copyright Silca 2 010 29 8.3.1 Cutting bit and double bit keys 1) Prepare the clamps with the required side facing the cutter and tracer point (fig. 38) (fig. 39). 2) Lock the clamps in the horizontal position by means of the pin (L). 3) Place the key to be cut into the left-hand clamp. Note: leave clearance at least 2 mm between the bit and clamp. 4) Raise the carriage and place the bit against the cutter (fig. 40). 5) Secure the original key in the right-hand clamp, placing the bit against the tracer point; this will ensure that the two keys are perfectly aligned. Note: choose a translation system with fixed or free carriage (chap.8.1.3, page 21) (Attention: not available on Duo Brazil version). 6) Proceed with cutting (fig. 41); if necessary, activate tilting to flare the cuts (chap.8.1.5, page 22). 7) Raise the carriage with the handle (H) and take the original key into contact with the tracer point to carry out cutting. 8) Take the carriage back with the handle (H), go on to the next cutting position and continue from point 7. 9) When cutting is finished, turn off the switch (U) and remove the keys. Fig. 40 Fig. 41 2 mm H

30 Copyright Silca 2 010 8.3.2 Cutting keys with central stop Note: check that the clamps are locked into the fixed position. 1) Prepare the clamps with the required side facing the cutter and tracer point. 2) Loosen the clamp handles slightly to allow the keys to enter. 3) Insert the original key into the right-hand clamp with the central stop up against the clamp (left-hand side) and the bit parallel to the clamp; tighten the knob (K) to secure the key. 4) Insert the key to be cut into the left-hand clamp with the central stop up against the clamp (left-hand side) and the bit parallel to the clamp; tighten the knob (K) to secure the key. Note: choose a translation system with fixed or free carriage (chap.8.1.3, page 21) (Attention: not available on Duo Brazil version). 5) Start the machine and proceed with cutting. 6) Raise the carriage with the handle (H) and take the cut key into contact with the tracer point to com- plete cutting. 7) Take the carriage back with the handle (H), go on to the next cutting position and continue from point 6. 8) When cutting is finished, turn off the switch (U) and remove the keys. Fig. 42 8.3.3 Cutting mail box keys ATTENTION: only on DUO and DUO BRAZIL versions. Note: check that the clamps are locked into the fixed position. 1) Prepare the clamps with the required side facing the cutter and tracer point. 2) Loosen the clamp handles slightly to allow the keys to enter. 3) Insert the original key into the right-hand clamp, using the end of the bit (towards the tip) as a refer- ence against the tracer point (fig. 43). 4) Insert the key to be cut into the left-hand clamp, using the end of the bit (towards the tip) as a refer- ence against the cutter. Note: choose a translation system with fixed or free carriage (chap.8.1.3, page 21) (Attention: not available on Duo Brazil version). 5) Start the machine and proceed with cutting. 6) Raise the carriage with the handle (H) and take the cut key into contact with the tracer point to com- plete cutting. 7) Take the carriage back with the handle (H), go on to the next cutting position and continue from point 6. 8) When cutting is finished, turn off the switch (U) and remove the keys. Fig. 43 K H K K K

DUO Copyright Silca 2 010 31 8.3.4 Cutting pump keys ATTENTION: some models only (see fig. 44). 1) Prepare the clamps with the bit key jaw turned 90° (fig. 44) (fig. 45). 2) Lock the clamps into the horizontal position by means of the pin (L). 3) Place the key to be cut into the left-hand clamp with the bit in contact with the clamp. 4) Secure the original key in the right-hand clamp with the bit in contact with the clamp. Note: choose a translation system with fixed or free carriage (chap.8.1.3, page 21) (Attention: not available on Duo Brazil version). 5) Start the machine and proceed with cutting. 6) Raise the carriage with the handle (H) and take the cut key into contact with the tracer point to com- plete cutting. 7) Take the carriage back with the handle (H), go on to the next cutting position and continue from point 6. 8) When cutting is finished, turn off the switch (U) and remove the keys. Fig. 44 90° max. 15 mm min. Ø min.3,5 max.7 mm 26 mm ATTENTION: some models only. The duplication is possible for keys with these characteristics. DUO and DUO BRAZIL 1 2 1 1

32 Copyright Silca 2 010 Fig. 45 The duplication is possible for keys with the following characteristics. DUO POWER max.20 mm max.7 mm max. 15 mm mn. Ø min.3,5 max.7 mm 14 mm 2 1 2 90° pump keys ROUND stem 1 2 pump keys FLAT stem (Mottura type) 2

DUO Copyright Silca 2 010 33 9 MAINTENANCE ATTENTION: for repairs or replacement of parts for maintenance, the ‘CE’ mark is guaranteed only if original spare parts provided by the manufacturer are used. Although the DUO key-cutting machine does not require special maintenance, it is advisable to check and, if necessary, replace the parts subject to wear, such as: the belt, cutting tool, brush, tracer point. Replacement is simple and can be carried out by the operator. CLEANING Keep the carriage and clamps free of chippings from the cutting operations by cleaning with a dry brush. ATTENTION: do not use compressed air! ATTENTION: to keep the machine well maintained we recommend using protective oil, e.g. WD40 or similar, applied to the burnished mechanical parts. This prevents oxidation of the parts in question (clamps, guides, carriages, etc.). Before starting any type of maintenance (checks or replacements), read the instructions below: • never carry out maintenance or servicing with the machine switched on. • always remove the mains plug. • follow all the instructions in the manual to the letter. • use original spare parts. • always check that any screws or nuts removed when replacing a piece are properly tightened. 9.1 Replacing the cutting tool In order to substitute the cutting tool you don’t need to remove the cutting tool cover. To replace a worn cutting tool, proceed as follows: ATTENTION: remove the mains plug. 1) Move the shield (W) to operate on the cutting tool to replace. 2) Slot the locking rod (standard) into the hole of the cutting tool shaft (fig. 46). 3) Use the spanner provided to loosen the cutting tool locking the nut. ATTENTION: the thread is: - left-handed for prismatic cutters (flat keys) - right-handed for saw cutters (bit, pump keys) 4) Remove the worn cutting tool. 5) Carefully clean the new cutting tool and its seat 6) Install the new cutting tool and tighten the nut. ATTENTION: the direction of cutter rotation is: clockwise for prismatic cutters, anticlockwise for saw cutters. 7) Remove the locking pin. Fig. 46 locking rod W

34 Copyright Silca 2 010 9.2 Access to the lower part ATTENTION: remove the mains plug. 1) Detach the wire from the key-cutting machine socket. 2) Remove the swarf tray (S) (fig.5, page 6). 3) Before to turn the machine onto its back take the carriages externally to the end of run (left-hand car- riage all to the left, right-hand carriage all to the right) to avoid contacts between cutter/tracer point and clamps during movement. 4) Turn the machine onto its back firmly holding it on handles (C and H) (fig. 47). Fig. 47 C H

DUO Copyright Silca 2 010 35 9.3 Replacing the brush When the brush no longer cleans off the burrs it must be replaced as follows. ATTENTION: remove the mains plug. 1) Place the locking rod (provided) in position on the motor shaft. 2) Use the Allen wrench (provided) to loosen the screw holding the brush in place (fig. 48). 3) Replace the brush and tighten the screw with the Allen wrench. 4) Remove the locking rod from the motor shaft. Fig. 48 9.4 Replacing and/or tightening the belt Worn or loose belts must be replaced or adjusted so as to ensure safe and proper operation of the cut- ting tool/ brush. Tension: ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig. 49). 2) Access the bottom part (chap.9.2, page 34) and loosen the 4 nuts (S1) of the plate motor (fig. 50). 3) Push the motor back until the belt is properly tightened. 4) Tighten the four nuts (S1). 5) Place the machine in position on the work bench. Fig. 49 locking rod brush holding screw tighten loosen T T Q1 Q1

36 Copyright Silca 2 010 Fig. 50 Belt replacement: ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig.49, page 35). 2) Remove the fan and remove the old belt, turning the m ain pu lley m anually and exerting a lit tle pressure on the belt to prize it out of its seat. 3) Fit the new belt by inserting it into the motor pul- ley then (exert a lit tle pressur e) into the m ain pulley, turning it manually. 4) Replace the fan and the top cover. Fig. 51 9.5 Replacing the tracer point Left-hand tracer point: ATTENZIONE:remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig.49, page 35). 2) Loosen the screw (G4) (fig. 52). 3) Loosen the grub screw (G3). 4) Loosen the tracer point by turning it anticlockwise until is fully released. 5) Fit the new tracer point and screw down to the end of run. 6) Tighten the grub screw (G3). 7) Tighten the screw (G4). 8) Re-set the machine as described in chap. 7.2, page 15. Fig. 52 S1 G3 G4

DUO Copyright Silca 2 010 37 Right-hand tracer point: ATTENZIONE:remove the mains plug. 1) Loosen the screw (N4). 2) Remove the worn tracer point (N). 3) Fit the new tracer point, pushing all the way in. En sure that the seat is clean. 4) Tighten the screw (N4). 5) Re-calibrate the m achine, foll owing the proce dure de - scribed in chap. 7.3, page 17. Fig. 53 9.6 Regulating left carriage depth The carriage o n the DU O can be regula ted to protect the clamps from co ming into contact with the tracer point or cutting tool. ATTENTION: the play between cutting too or tracer point and clamps must be at least 0.1 mm. Should it be different from this, proceed as fol- lows: ATTENTION: remove the mains plug. 1) Release the carriage, raise against the cut- ting tool and take to the end of its run (fig. ) 2) Remove the chippings tray (S). 3) Release the nut (S3) (fig. ) with the spanner. 4) Use the Allen wrench to screw or unscrew the grub screw in order to move the carriage away from or towards the tracer point and cutting tool. 5) Tighten the nut. Fig. 54 9.7 Replacing the fuses ATTENTION: remove the mains plug. 1) Unplug the power cable from the key-cutting machine socket. 2) Remove the fuses box placed below the key-cutting machine socket (V) (fig. 55). 3) Replace the fuses (V1) (fig. 55). 4) Close the fuses box and connect the power cable ATTENTION: fuses must always be replaced with others of the same type (rapid) and with the same Amps (4 Amp for 230V - 8 Amp for 120V). Fig. 55 N4 N allen key 0,1mm S3 fuses box V1 V

38 Copyright Silca 2 010 9.8 Replacing main switch ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig.49, page 35). 2) Detach the 4 connectors (V2) paying special attention to their position. 3) Remove the switch making pressure on the tabs with a screwdriver. 4) Fit the new main switch. 5) Reconnect the 4 connectors (V2). 6) Replace the top cover and secure with the 4 screws (Q1). Fig. 56 Fig. 57 V2

DUO Copyright Silca 2 010 39 9.9 Replacing motor on switch ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig.49, page 35). 2) Detach the 4 connectors (S2) (fig. 58) paying special attention to their position. 3) Use a screwdriver to turn down the internal switch fixing tabs and pull it out. 4) Fit the new switch in its seat and r econnect the 4 connectors (S2) paying special attention to their position. 5) Replace the top cover and secure with the 4 screws (Q1). Fig. 58 S2

40 Copyright Silca 2 010 9.10 Replacing motor/condenser ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q) (fig.49, page 35). 2) Detach the 4 connectors (S2) from the motor ignition switch and condenser (fig.58, page 39). 3) Unscrew the earth cable nut (S5) (fig. 59). 4) Turn the machine onto its back (chap.9.2, page 34). 5) Loosen the 4 screws (S1) (fig. 60) on the motor fixing plate and remove the belt (chap.9.4, page 35). 6) Loosen completely only the 2 lower screws (S1) the motor fixing plate and pull downwards. 7) Install the new motor and tighten the 4 screws (S1) slightly. 8) Place the machine in position on the work bench. 9) Install the belt and tighten it, and tighten the 4 screws (S1) (fig. 60) of the plate motor. 10) Connect the 4 connectors (S2) (fig. 58) to the motor on switch and fit the earth cable to its screw with the nut (S5) (fig. 59). 11) Replace the condenser wires. 12) Place the machine in position on the work bench. 13) Replace the top cover and secure with the 4 screws (Q1). Fig. 59 Fig. 60 S5 S1

DUO Copyright Silca 2 010 41 9.11 Replacing lamp ATTENTION: remove the mains plug. 1) Loosen the 4 screws (Q1) and remove the top cover (Q). 2) Loosen the light bulb (this may be facilitated by removing the shield (R1) or (R2). 3) Screw the new light bulb into the lamp. 4) Replace the top cover and secure with the 4 screws (Q1). Fig. 61 T T Q1 Q1 R1 R2

42 Copyright Silca 2010 10 DISPOSAL For correct disposal please refer to current standards. INFORMATION FOR USERS OF PROFESSIONAL EQUIPMENT From "Actuation of Directive 2012/19/EU regarding Waste Electrical and Elec- tronic Equipment (WEEE)" The symbol of a crossed waste bin found on equipment or its packing indicates that at the end of the product’s useful life it must be collected separately from other waste so that it can be properly treated and recycled. In particular, separate collection of this professional equipment when no longer in use is organised and managed: a) directly by the user when the equipment was placed on the market before 31 December 2010 and the user personally decides to eliminate it without replacing it with new equivalent equipment designed for the same use; b) by the manufacturer, that is to say the subject which was the first to introduce and market new equip- ment that replaces previous equipment, when the user decides to eliminate equipment placed on the market before 31 December 2010 at the end of its useful life and replace it with an equivalent product designed for the same use. In this latter case the user may ask the manufacturer to collect the existing equipment; c) by the manufacturer, that is to say the subject which was the first to introduce and market new equip- ment that replaces previous equipment, if it was placed on the market after 31 December 2010; Suitable separate collection for the purpose of forwarding discarded equipment for recycling, treatment or disposal in an environmentally friendly way helps to avoid possible negative effects on the environment and human health and encourages re-use and/or recycling of the materials making up the equipment. The sanctions currently provided for by law shall apply to users who dispose of products in unauthorised ways.

DUO Copyright Silca 2 010 43 11 ASSISTANCE Silca provides full assistance to purchasers of the DUO key-cutting machine. To ensure complete safety for the operator, any job not specified in this manual should be carried out by the manufacturer or in the special Service Centres recommended by Silca. On the back cover of this manual is a list of the manufacturer’s addresses; listed below are the address- es of specialised Service Centres. 11.1 How to request service The guarantee attached to DUO key-cutting machines ensures free repairs or replacements of faulty parts within 24 months of purchase. All other service calls must be arranged by the customer with Silca or with a Silca service centre.

CE DECLARATION OF MACHINE COMPLIANCE SILCA S.p.A. - VIA PODGORA 20 ( Z.I.) 31029 VITTORIO VENETO (TV) - (ITALY) TEL. 0438 9136 - FAX. 0438 913800 Declares under its own responsibility that the Key-cutting machine model DUO complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN ISO 12100 – 1 : 2003 EN ISO 12100 – 2 : 2003 EN ISO 14121 – 1 : 2007 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN 61000 – 6 – 3 EN 61000 - 6 – 1 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage) | 09 | and with the EN 60204-1 : 2006 Standards Claudio Tomasella of the Silca S.p.A. Research & Development Division is authorized to create a Technical File. General Manager Basic Production Center

31029 VITTORIO VENETO (TV) Tel. 0438 9136 Fax 0438 913800 E-mail: [email protected] www.silca.biz Members of the Kaba Group