Silca REKORD 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: september 2009 Printed in Vittorio Veneto by SILCA S.p.A. via Podgora, 20 (Z.I.) 31029 VITTORIO VENETO (TV) - Italy 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 WORKING PART ............................................................................................6 3 MACHINE DESCRIPTION ...............................................................................7 3.1 Technical Data ......................................................................................8 3.2 Electric circuit .......................................................................................9 4 ACCESSORIES PROVIDED .........................................................................10 5 MACHINE INSTALLATION and PREPARATION ........................................11 5.1 Checking for damage .........................................................................11 5.2 Environmental conditions ...................................................................11 5.3 Positioning ..........................................................................................11 5.4 Removing the blocks ..........................................................................12 5.5 Separate parts ....................................................................................12 5.6 Connection to the mains .....................................................................12 5.7 Description of work station .................................................................13 5.8 Graphics .. ...........................................................................................13 6 MACHINE REGULATION AND UTILIZATION .............................................14 6.1 Checking and setting ..........................................................................14 6.2 Calibration .. ........................................................................................14 7 KEY CUTTING ...............................................................................................16 7.1 Key cutting ..........................................................................................16 8 MAINTENANCE ............................................................................................20 8.1 Replacing the cutting tool ...................................................................20 8.2 Replacing the brush ............................................................................21 8.3 Replacing and/or tightening the belt ...................................................21 8.4 Replacing the tracer point ...................................................................22 8.5 Regulating carriage depth ..................................................................23 8.6 Replacing the fuses ............................................................................23 8.7 Access to the lower part ......................................................................24 8.8 Replacing main switch.........................................................................24 8.9 Replacing motor/condenser.................................................................25 8.10 Replacing lamp feed (transformer) .....................................................26 8.11 Replacing lamp set/lamp protection ....................................................26 8.12 Replacing motor start switch ...............................................................27 9 DISPOSING OF MACHINE ............................................................................28 10 ASSISTANCE ................................................................................................29 10.1 How to request service .......................................................................29

REKORD Copyright Silca 2 007 3 GUIDE TO THE MANUAL This manual has been produced to serve as a guide for users of the REKORD 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 - Maintenance .................................................................................................................... Ch.8 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 1) Head 2) Rim 3) Stop 4) Stem 5) Tip 6) Back 7) Cuts 8) Stem 1 1 1 1 3 3 3 3 7 7 8 2 2 2 5 5 5 5 4 4 6 6 only for SOFERversion only for BRAZIL version 1 8 3 5

4 Copyright Silca 2 007 GENERAL INTRODUCTIONS The REKORD key-cutting machine has been designed according to the specifications of the Machine Directives. From the design stage risks for the operator have been eliminated in all areas: transport, key- cutting, 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 th e machine warning the operator to use goggles during the cutting 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 REKORD 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 REKORD and benefit from its potential. Instructions manual The instructions manual provided with the machine is essential to its proper use and to carry out the 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 REKORD key-cutting machine is built entirely to standards. The operations for which it has been designed are easily carried out at no risk to the operator. The a doption o f g eneral safety precautions (wearing pro tective gog gles) an d observatio n of the instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate. The REKORD 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 right-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 REKOR D key-cutting machine is provi ded w ith an iden tification la bel w hich show s the seria l number (fig. 2). Fig. 2 (*) see chap. 9 "DISPOSING OF MACHINE", page 28.

REKORD Copyright Silca 2 007 5 1 TRANSPORT The REKORD key-cutting machin e is easily transpor ted and is not da ngerous to ha ndle. The packed machine can be carried by one person. 1.1 Packing The REKORD is packed in a strong cardboard box, the dimensions of which are shown in fig. 3, 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. 3 1.2 Transport To avoid damaging the REKORD it must alw ays be transported in its packin g 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 manufacturers for repairs or servicing). 4) check the contents of the box, which should comprise: - 1 REKORD key-cutting machine packed in a protective shell. - 1 set of documents, including: operating manual, spare parts list and guarantee. - 1 connecting wire. - 1 carriage lever handle; - 1 tool kit. 5) remove the key-cutting machine from the protective shell. 1.4 Handling the machine When the REKORD 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. 490 540 380 Keep dry This side up Handle with care

6 Copyright Silca 2 007 2 WORKING PARTS Fig. 4 A - carriage lever handle B - carriage release lever C - chippings tray C1 - tool tray D - carriage movement lever E - clamps F - clamp knobs G - gauge knobs H - gauge tabs H1 - lamp I - tracer point J - tracer point locking grub screw K - centesimal ring L - cutting tool M - top cover N - motor on switch O - main switch P - brush Q - protective pad R - clamp carriage S - motor U - fuses V - supply socket W - protective belt cover B C A C1 D E G F L M O P R S H1 w U V I J K N H Q

REKORD Copyright Silca 2 007 7 3 MACHINE DESCRIPTION REKORD is a professional cutting machine for flat keys used with cylinder, car locks and cruciform keys. 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 (O) pow ers the machine and illuminates the warning light (H1) to indicate that current is on. ATTENTION: Switch (O) 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 The motor on switch (N) is placed on the left-hand side of the REKORD key-cutting machine. ATTENTION: the illuminated switch remains on to indicate that the key-cutting machine has been started (cutter in motion). Motor and transmission unit The motor has belt transmission. The transmission unit is placed on the left of the motor and activates the brush (P) and cutting tool (L). These components are protected by two covers: - protective belt cover (W), - top cover (M). Clamp carriage The clamp carriage (R) consisting of two clamps, is fitted to the horizontal movement carriage, controlled by lever (D) and is provided with a handle (A) under which can be found the carriage release button (B). The carriage movement by means of gears, allows high precision movements which greatly facilitate all cutting operations. The carriage is fully protected by a special pan el designed to prevent the accumula tion of dust an d chippings from the work process. The machine is designed with a ramp along which chippings can fall into the special chippings tray (C), placed under the carriage and easily removable for emptying and cleaning. Cutting unit The cutting unit contains the actual working parts of the REKORD key-cutting machine, which operate together to cut and finish keys "read" from the originals. The working parts are described below: • Brush The brush (P) is used to eliminate burrs from the cuts and is made of non-abrasive material. • Cutting Tool The cutting tool (L) is the part of the REKOR D used for cutting key blanks. The cutting tool is in H SS super rapid steel and is protected by a special cover (M) to ensure safe operation. • Tracer point The tracer point (I), used for reading the profile of the key to be copied, is housed on the left-hand side of the machine base. A centesimal ring (K) ensures regulation of the depth. • Clamps The clamps (E) have four sides which rotate to allow the key to be perfectly secured on its back or in profile (fig. 13-B). • Clamp knobs The clamps are locked by two anatomical knobs (F) which ensure perfect grip on the keys with only slight locking pressure. • Calibration tabs The clamps have two gauge tabs (H) with which to adjust key alignment.

8 Copyright Silca 2 007 3.1 Technical Data ELECTRICAL PROPERTIES: - 230V - 50/60Hz 370W 2A - 120V - 60Hz 560W 4,6A CUTTING TOOL: HSS Super Rapid Steel MOTOR: One-speed single phase - 230V - 50/60Hz; 1350/1620 rpm 0,18 Kw - 120V-60Hz; 1620 rpm 0,18 Kw MOVEMENTS: by gear on rectified carriage CLAMP: rotating with four sides, high precision MAXIMUM LENGTH OF CUTS: 43 mm (carriage run) DIMENSIONS: width: 330mm (with max. lever encumbrance 510mm) depth: 430mm height: 270mm SONOROUS PRESSURE: Leq. = 82.5 dB (brass keys) SONOROUS PRESSURE: Leq. = 87.5 dB (iron keys) Note: the equivalent sonorous pressure for the iron keys during the normal use (around 50 keys a day) it is inferior to 85 dB. WEIGHT: 19 kg.

REKORD Copyright Silca 2 007 9 3.2 Electric circuit The REKORD key-cutting machine is provided with a single phase one-speed motor; - 1350 rpm, consumes approximately 0.18 Kw, absorption 2A (230V-50Hz) - 1620 rpm, consumes approximately 0.18 Kw, absorption 2A (230V-60Hz) - 1620 rpm, consumes approximately 0.18 kw, absorption 4,6A (120V-60Hz) The main parts of the electric circuit on the REKORD are listed below: 1) Main plug with fuses 2) Safety main switch 3) Illuminated switch 4) Motor: 230V a.c. 50/60Hz - (120V a.c. 60Hz) 5) Condenser 6) Feeder 7) 6 LED circuit board (lamp) black red Feeder (lamp) 6 LED circuit board brown light blue light blue brown yellow/green 1 2 3 6 4 7 5 ( ) ( ) (lamp)

10 Copyright Silca 2 007 4 ACCESSORIES PROVIDED To ensure trouble-free working with the REKORD, it is advisable to always have certain spare parts on hand. It is advisable to always have a tool box containing: tools, cutting tools, brushes, belts and small replacement parts. REKORD is supplied with a full range of accessories. The accessories provided by Silca are all that is ne cessary to carry out the operations for which the machine is designed. Fig. 5 C1 ADHESIVE LABEL “DANGEROUS MOBILE PARTS” STEEL PIN Ø 1,20 2 pcs STEEL PIN Ø 1,70 2 pcs STEEL BAR 2 pcs 5X20 FUSES (2 pcs) 4 Amps rapid (230V) 8 Amps rapid (120V) 2,5 mm ALLEN KEY 3 mm ALLEN KEY 19 mm SPANNER 10 mm SPANNER CUTTING TOOL UNCLAMPING PIN ADJUSTING BAR 2 pcs 4 mm ALLEN KEY 5 mm ALLEN KEY ATTENTION DANGEROUS MOBILE PARTS

REKORD Copyright Silca 2 007 11 5 MACHINE INSTALLATION AND PREPARATION The REKORD 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. 5.1 Checking for damage The REKORD 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. 5.2 Environmental conditions To ensure that the best use is made of the REKORD 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 0 to 40°C - relative humidity: approx. 60% 5.3 Positioning Place the key-cutting machine on a horizontal surface, solid enough to take the weight (19 Kg). To facilitate operation and maintenance, install the machine with a space of at least 200 mm on all sides (fig. 6). Ensure that the machine stands pe rfectly balanced on the four fee t. Vibration is avoided when the machine 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. 6 200 mm 200 mm 200 mm

12 Copyright Silca 2 007 5.4 Removing the blocks Remove the 2 blocks: on the carriage movement and between cutter and jaw (fig. 7). Fig. 7 5.5 Separate parts The separately pa cked pa rts must b e installed on th e REKORD ke y-cutting machine by the purchaser, as follows: Connection wire Connect the key-cutting machine p ower cable to the electricity mains (fig. 8). Fig. 8 Carriage lever handle Screw the carriage handle as shown in fig. 9. Fig. 9 5.6 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. electricity supply power cable

REKORD Copyright Silca 2 007 13 5.7 Description of work station The key-cutting machine needs only one operator, who has the following controls at his/her disposal: - Switch on the lamp by activating the main switch (O) located on the right-hand side of the machine. - The motor on switch (N), located on the left-hand side of the machine has a warning light to show that the key-cutting machine is live. - Carriage movement lever (D) - Carriage handle lever (A) - Carriage release lever (B) - Gauge knob (G). Fig. 10 5.8 Graphics A B D N G THE USE OF PROTECTIVE GOGGLES IS COMPULSORY ATTENTION DANGEROUS MOBILE PARTS Place the adhesive label “Dangerous mobile parts” (ch .4, p age 10 ) as shown.

14 Copyright Silca 2 007 6 MACHINE REGULATION AND UTILIZATION 6.1 Checking and setting The cutting tool on the REKOR D is the part used to cut the ke y blanks and should be period ically checked and replaced, if necessary. Every time the cutting tool is changed, and during periodical operational tests, check calibration. 6.2 Calibration The REKORD 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. 11). The axis setting for the REKORD is fixed and is established on assembly in our workshops Fig. 11 Depth calibration: Depth calibration is regulation of the cutting depth (fig. 11-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. 12-B). 3) Check that the adjusting keys adhere properly to the clamps (fig. 12-B). 4) Turn the gauge rod (G) towards the operator so that the gauges come into contact with the adjusting keys (fig. 12-B). Lower the gauge rod (G). 5) Release the carriage by raising the release lever (B) (fig. 4). 6) Raise the carriage and take up to the cutting tool. 7) Take the keys into contact with the cutting tool and tracer point. 8) Turn the cutting tool anticlockwise manually and check that it skims the adjusting keys in several places. 9) If necessary, regulate the depth of the cut with the micrometric tracer point, as follows: a) loosen the screw holding the tracer point (J). b) turn the grub screw (K) clockwise to advance the tracer point. c) turn the grub screw (K) anticlockwise to return. ATTENTION: each notch on the centesimal ring corresponds to 0,025 mm (fig. 12-A). 10) Repeat these operations until regulation is complete, then tighten the tracer point locking grub scre (J). 6 4 8 9 0 cutting I II III IV V VI cutting space depth B A

16 Copyright Silca 2 007 7 KEY CUTTING 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 N) only after completing the operations on the carriage (securing the keys, etc.). - Keep hands away from the cutting tool in motion. 7.1 Key cutting 1) Turn the clamps to find the appropriate side for securing the key (fig. -B). 2) Loosen the knobs (F) by a couple of turns (fig. -A). 3) Raise the lower part of the clamps and turn to the required position: - Side A of the clamp: for keys to be fitted on their backs (fig. -B) - Side B of the clamp: for keys placed on their backs and having cuts with a depth of less than 3,9 mm (fig. -B)) - Side C and D of the clamp: for keys to be cut on both sides and locked on the groove (fig. -B) Securing the keys in the jaws 1) Position the original key (left-hand jaw) and key blank (right-hand jaw), ensuring that: a) the keys are positioned and secured in the clamp; b) the key stop is resting against the calibration tabs (H); 2) secure the keys by closing the clamps with the knobs (F). Fig. 13 D A B C F H A B A SOFER Version D A B C B F H

REKORD Copyright Silca 2 007 17 Key cutting When the R EKORD key-cutting machine has been turned on by means of switch (O) it i s ready for cutting: 1) Make sure the gauge rod (G) has been lowered. 2) Take the carriage up to the tracer point and cutting tool by releasing the push lever (B). 3) To copy the key, move the carriage sideways from right to left by means of the lever (D). 4) Turn off the machine with main witch (O) before removing the duplicated key. 5) Remove the keys from the clamps. 6) Turn on the machine with switch (O) and smooth off the key edges by means of the brush (P). Fig. 14 D A B C F H A B BRAZIL version key blank original key

18 Copyright Silca 2 007 Using the accessories The accessories provided with the REKORD 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. 15, fig. 15-C). For keys with narrow, thin stems, two pins must be used (fi g. 15-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. 15-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. 15 A B C pin

REKORD Copyright Silca 2 007 19 Using the bars The bars provided are used for cutting pin keys and as a tip rest for locking keys with no stop (fig. 16). Cutting pin keys using bars The pin keys (90°) can be cut with the REKORD clamps and the aid of the bars. Positioning pin 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 (fig. 16). 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. 16 Tip stop with a bar The bars can be used with keys which have no stop (fig. 16). 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. 17 bar

20 Copyright Silca 2 007 8 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 REKORD key-cutting machin e does not r equire special maintenance, it is advisabl e 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.). Do not contaminate the electronic parts with the oil. 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. 8.1 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) Slot the locking rod (standard) into the hole of the cutting tool shaft (fig. 18). 2) Use the spanner provided to loosen the cutting tool locking the nut. ATTENTION: the thread is left-handed. 3) Remove the worn cutting tool. 4) Carefully clean the new cutting tool and its seat. 5) Install the new cutting tool and tighten the nut. ATTENTION: the tool rotates clockwise. 6) Remove the locking pin. Fig. 18 locking rod loosen tighten

REKORD Copyright Silca 2 007 21 8.2 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. 19). 3) Replace the brush and tighten the screw with the Allen wrench. 4) Remove the spanner from the motor shaft. Fig. 19 8.3 Replacing and/or tightening the belt Worn or loose belts (T) must be replaced or adjusted so as to ensure safe and proper operation of the cutting tool/ brush. Tension: ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q) (fig.4, page 6). 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Loosen the 4 screws (S1) of the plate motor (fig. 22). 4) Push the motor down until the proper belt ten- sion is obtained. 5) Tighten the four screws. Fig. 20 Replacement: ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q). 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Remove the brush (fig. 19). 4) Remove the 3 screw (M2) (fig. 19) to remove the protective cover (fig. 22) 5)  Loosen the 4 screws (S1) of the plate motor (fig. 22) 6) Raise the motor and remove the worn belt. 7) Fit the new belt. 8)  Replace the motor in its previous position. 9) Tighten the 4 screws. 10) Replace the belt cover 11) Replace the brush 12) Replace the top cover Fig. 21 locking brush holding rod screw loosen tighten M1 M2

22 Copyright Silca 2 007 Fig. 22  FOR VERSIONS WITH BELT TIGHTENERS (P1) (Fig.23) - Loosen the screw (P2) and raise the belt tightener in order to remove the belt. - Push the belt tightener downwards to tighten the belt. - Secure the belt tightener with the screw (P2). Fig. 23 FOR VERSIONS WITH BELT TIGHTENERS (P1) (Fig.23) - Push the belt tightener downwards to tighten the belt. - Secure the belt tightener with the screw (P2). 8.4 Replacing the tracer point To replace the tracer point (I) (fig. 25), proceed as follows: ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q). 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Loosen the screw (K1). 4) Loosen the grub screw (J). 5) Loosen the tracer point by turning it anticlockwise until is fully released. 6) Fit the new tracer point and screw down to the end of run. 7) Tighten the grub screw (J). 8) Tighten the screw (K1). 9) Re-set the machine as described in chap. 6, page 14. Fig. 24 Fig. 25 S S1 P2 P1 K1 K J I

REKORD Copyright Silca 2 007 23 8.5 Regulating carriage depth The carriage on the REKORD can be regulated to protect the clamps from coming into contact with the tracer point or cutting tool. ATTENTION: the play between cutting tool/tracer point and clamps must be 0.1 mm. Should it be different from this, proceed as follows: ATTENTION: remove the mains plug. 1) Release the carriage, raise against the cutting tool and take to the end of its run (fig. 26). 2) Remove the chippings tray (C) and tool holder (C1). 3) Release the nut with the spanner (fig. 26). 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. 26 8.6 Replacing the fuses ATTENTION: remove the mains plug. 1) Unplug the power cable from the key-cutting machine socket. 2) Turn the key-cutting machine round so as to reach the fuse housing on the back. 3) Remove the fuses box placed below the key-cutting machine socket (V) (fig. 27). 4) Replace the fuses (U) (fig. 27). 5) 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 Amps for 230V; 8 Amps for 120V. Fig. 27 allen wrench 0,1 mm spanner fuse box U

24 Copyright Silca 2 007 8.7 Access to the lower part ATTENTION: remove the mains plug. 1) Detach the wire from the key-cutting machine socket. 2) Remove the double box (tool holder/swarf tray) (C) and (C1). 3) Turn the machine over onto its back. 4) Loosen the 6 screws (Y) to remove the bottom grate. Fig. 28 8.8 Replacing main switch ATTENTION: remove the mains plug. 1) Access the bottom part (see ch. 8.7). 2) Detach the 4 connectors (Y1) paying special attention to their position. 3) Use a screwdriver to lower the internal tabs fixing the switch, then pull it out. 4) Fit the new main switch. 5) Reconnect the 4 connectors (Y1). 6) Replace the bottom grate and secure with the screws (Y) (fig. 28). 7) Turn the machine back into place on the work bench. Fig. 29 Y Y1

REKORD Copyright Silca 2 007 25 8.9 Replacing motor/condenser Motor ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q). 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Detach the 4 co nnectors (S2 ) from the mo tor o n switch. 4) Loosen the 4 screws (S1) ( fig. 22 ) on the motor fixing plate and remove the belt. 5) Loosen completely only the 2 lower screws (S1) the motor fixing plate and pull downwards. Fig. 30 Condenser ATTENTION: remove the mains plug. - Access the bottom part (see ch. 8.7) - Remove the motor (see ch. 8.9 - Replacing motor) - Loosen the nut (Z) (fig. 32) and remove together with the washer. - Loosen the 4 screws (S4) on the motor box and re- move. - Loosen the 2 condenser connection screws (X1). - Loosen the nut on the wire grommet (X) and remove the condenser. - Fit the new conden ser, taking the wire through the nut (X) replace the motor box and secure with the 4 screws (X1). - Tighten the grommet nut (X), replace the motor box and secure with the 4 screws (S4). - Replace the condenser (see points 9 to 13). - Loosen the 4 screws (S3) on the motor fixing plate. - Secure the new motor on the fi xing plate with the screw (S3). - Replace the motor. Fig. 31 6) Place the machine in position on the work bench. 7) Install the belt and tighten the 4 screws (S1) (fig. 22) of the plate motor. 8) Connect the 4 connectors (S2) (fig. 30) to the motor on switch and fit the earth wire to its screw with the nut (S5) (fig. 34). 9) Replace the condenser and secure with washer and nut. 10) Replace the bottom grate and secure with the screws (Y) (fig. 28). 11) Place the machine in position on the work bench. 12) Replace the top cover and secure with the 3 screws (M1). 13) Replace the protective pads (Q). Fig. 32 Fig. 33 S2 S3 Z X X1 S4

26 Copyright Silca 2 007 Fig. 34 8.10 Replacing lamp feed (transformer) ATTENTION: remove the mains plug. 1) Access the bottom part (see ch. 8.7). 2) Loosen the 2 low voltage connector screws (Q1) remove and place in their seat on the new transfor- mer, securing with the 2 screws. 3) Loosen the 2 mains connector screws (Q3) remove and place in their seat on the new transformer, securing with the 2 screws. 4) Loosen the screws (Q2) fixing the transformer to the bottom plate and remove. 5) Place the new transformer in position and secure with the screws (Q2). 6) Replace the bottom grate and secure with the screws (Y) (fig.28, page 24). 7) Place the machine in position on the work bench. Fig. 35 Fig. 36 8.11 Replacing lamp set/lamp protection Lamp set ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q). 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Access the bottom part (see ch. 8.7). 4) Loosen the 2 low voltage connector screws (Q1) and remove them. 5) Position the machine upright again. 6) Loosen the 2 lamp fixing screws (L1) and remove. 7) Replace the top cover and secure with the 3 screws (M1). 8) Turn the machine over onto its back. 9) Connect the 2 connectors in the low voltage supply outlet seat and secure with the 2 screws (Q1). 10) Replace the bottom grate and secure with the screws (Y) (fig. 28). 11) Place the machine in position on the work bench. S5 Q1 Q2

REKORD Copyright Silca 2 007 27 Lamp protection ATTENTION: remove the mains plug. 1) Remove the two protective pads (Q) 2) Loosen the 3 screws (M1) and remove the top cover (M). 3) Loosen the 2 lamp fixing screws (L1) and remove. 4) Loosen the 2 screws (L2) in order to remove the lamp protection (L3). 5) Fit the new protection and secure with the 2 screws (L2) 6) Replace the lamp unit and secure with the 2 screws (L1) making sure the wiring is positioned to- wards the bottom of the machine. 7) Replace the top cover and secure with the 3 screws (M1). Fig. 37 Fig. 38 8.12 Replacing motor on switch ATTENTION: remove the mains plug. 1) Access the bottom part (see ch. 8.7). 2) Detach the 4 connectors (S2) (fig. 39) 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 reconnect the 4 connectors (S2) paying special attention to their position. 5) Replace the bottom grate and secure with the screws (Y) (fig. 28). 6) Place the machine upright on the work bench. Fig. 39 L1 L2 S2

28 Copyright Silca 2 007 9 DISPOSING OF MACHINE EU regulations establish special arrangements for the disposal of waste (**). Waste deriving from cutting operations Although residue coming from the key-cutting operations is classified as special waste, it is included in solid urban waste (SUW) as metal wool. Such waste is sorted according to its classification under current Italian and EU law and consigned to the proper disposal units. Cases where waste can be considered contaminated or containing toxic/harmful substances sufficient to transform it from SUW to toxic/harmful waste, are listed in the enclosures to current Italian and EU waste disposal regulations. Re-cycling is a recommended ecological practice. Packing The REKORD is consigned in a cardboard packing box which can be re-used if undamaged. When it is to be thrown away it is cl assified as solid urban waste and should be placed in the special paper collecting bins. The protective shell containing the ma chine is in polymer, classified as SUW, and can th erefore be placed in an ordinary waste bin. INFORMATION FOR USERS as per art. 10 of Directive 2002/96/CE of 27/01/2003 regarding waste from electric and electronic appliances (RAEE), • The symbol illustrated above, also found on the machine, indicates that it has been placed on the market and must be included in separ ate rubbish collection when t he user wishes to dis pose of it (including all components, sub-assemblies and consumables that are integrated in the product). • For information about the collection sys tem for su ch appliances please c ontact SILCA S.p.A. or another subject registered in the various National Rolls for other countries in the European Union. Household waste (or of similar origin) can be included in the separate collection system for urban waste. • On purchasing a new appliance of equivalent type, the old one can be consigned to the dealer. The dealer will then contact whoever is responsible for collecting the appliance. • Suitable separate collection of the unused appliance and its dispatch for treatment, recove ry and environmentally compatible disposal, makes it possible to avoid potential negative effects on the environment and human health, and aids recycling and the recovery of the materials used. • Unauthorised disposal of the product by u sers involves the application of the s anctions provided for in received Directives 91/156/CE and 91/689/CE (**) "Waste" is any substance or object deriving from human activity or natural cycles, thrown away or to be thrown away.

REKORD Copyright Silca 2 007 29 10 ASSISTANCE Silca provides full assistance to purchasers of the REKORD 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 th is manual is a list of the manufacturer’s add resses; listed bel ow are the addresses of specialised Service Centres. 10.1 How to request service The guarantee attached to R EKORD key-cutting machines ensures fre e repairs or repl acements 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 REKORD complies with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/CE (Machines) and with the EN 12100-1:2003 / EN 12100-2:2003 Standards European Union DIRECTIVE 2004/108/CE (Electromagnetic Compatibility) and with the EN 55022 : 1998 + A1 : 2000 + A2 : 2003 EN 61000 – 3 – 2 : 2000 + A2 : 2005 EN 61000 - 3 – 3 :1995 + A1 : 2001 Standards European Union DIRECTIVE 2006/95/CE (Low Voltage ) | 07 | and with the EN 60950 – 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

CENTROS DE ASISTENCIA - CENTROS DE ASSISTÊNCIA - BIJSTANDSCENTRA COUNTRY COMPANY ADDRESS CITY AREA CODE PHONE FAX e-mail Algeria Sarl Maghreb Clés Coopérative Ettadhamoune Local 21/A Badjarah / Alger 16209 +213-21-264934 +213-21-264888 [email protected] Argentina Distribuidora Frappampino S.r.l. La Rioja, 483 Cordoba 5000 +54-351-4216368 +54-351-4229003 [email protected] Australia Locksmiths' Supply Co. Pty Ltd. 140/158 Dryburgh St. North Melbourne VIC 3051 +61-39-3297222 +61-39-3281731 [email protected] Austria Erwe Gmbh Feldgasse, 16 Feldkirchen A-9560 +43-42762816 +43-42765054 [email protected] Belgium Duitman Bvba Zinkstraat 13 Halle 1500 +32-2-3831620 +32-2-3831622 [email protected] Brazil Kaba Do Brasil Ltda. Rua Guilherme Asbahr Neto 510 São Paulo 04646- 001 +55-11-5545-4510 +55-11-5545-4515 [email protected] Bulgaria Intesa S.r.l. 1, Kukush Sofia 01309 +359-2-8211425 +359-2-8211347 [email protected] Burkina Faso Diallo Mamoudou Av.Houari Boumedienne Porte N. 1651 01BP / 2957 Ouagadougou 01 +226-710448 +226-710002 [email protected] China Silca China Xinhua Industrial Zone Guanghai County, Taishan, Canton +86-750-5325698 +86-750-5315655 [email protected] Colombia Flexon Llaves S.A. Av.Carrera 70 No.99 - 55 Entrada 1 Bogotà +571-2538300 +571-5331842 Croatia Ferrotechna d.o.o. Japodska, 66c Pula 52100 +385-52-503-529 +385-52-502-609 +385-52-503-529 [email protected] Cyprus G.H. Yacoubian Ltd. 74/B, Regaena Street Nicosia +357-22-663525 +357-22-669009 [email protected] Czech Republic H&B Plus. s.r.o. Zatecká, 8 Plzen 30148 +420-377-225903 +420-377-225904 [email protected] Denmark Agenturcentret A.S Brydehusvej 20 Ballerup 2750 +45-70111211 +45-70111221 [email protected] Egypt Gam Transworld 23 Omer Ibn El-Khatar Street Heliopolis El Cairo +20-2-22404705 +20-2-26441401 +20-2-22404705 [email protected] Finland Hardware Group Finland Oy. (Hgf Ltd) Luostarinportti 5 Kirkkonummi 02400 +358-9-2219490 +358-9-2962186 [email protected] France SILCA S.A.S. 12, Rue de Rouen B.P.37 Z.I. Limay Porcheville 78440 +33-1-30983500 +33-1-30983501 [email protected] Germany SILCA GmbH Siemensstrasse, 33 Velbert 42551 +49-2051-2710 +49-2051-271172 [email protected] Greece Chrisikos K. Ioannhs 7 Pipsou St. Thessalonik TK 54627 +30-2310-510336 +30-2310-521651 [email protected] Greece F. Sotiropoulos & Son O.E. Patission Str., 110 Athens 11257 +30-210-8234009 +30-210-8238480 [email protected] Greece GEMKA-Karidis G. & Sons OE Lykoyrgoy St. 14-16 Athens 10552 +30-210-3243000 +30-210-3249571 [email protected] Greece Fr.lli Raptakis Pili Iisou 10 Iraklion - Crete +30-2810-285000 +30-2810-280165 [email protected] Guinea Soguintec S.A. Calle Abilio Baloboa Malabo - Provincia del Bioko Norte +240-556618 Holland Duitman B.V. Aquamarijnstraat 5 7554 NM - Hengelo +31-74-2452520 +31-74-2452522 [email protected] Holland H. Cillekens & Zn. B.V. Metaalweg, 4 JB Roermond 6045 +31-475-325147 +31-475-325148 [email protected] Holland Steenhauer B.V. Oude Raadhuisstraat 1 Ap Leidschendam 2266 +31-70-3177262 +31-70-3177333 [email protected] Hong Kong Professional Lock Centre Co. Ltd. Unit A-D, 9/F. Gemstar Tower, 23 Man Lock Street Hunghom, Kowloon, Hong Kong +852-23302268 +852-23302082 [email protected] Hungary Kaba Elzett Megyeri út 51 Budapest 1044 +36-1-3501011 +36-1-3290692 [email protected] India Minda Silca Engineering Ltd. Plot No. 37, Toy City Greater Noida 201308 +91-987-397630 +91-987-397631 +91-120-2351301 [email protected] Iran Klidavarshayan Co. No.73 Stakhr. St - Emam Khomaini Ave. Tehran +98-216-6702757 +98-216-735649 [email protected] Israel A.M.C.I. Locksmith Supply Ltd. 22 Efal Street Kiryat Aryeh P.O.Box 3667 Petah Tikva 49130 +972-3-9230331 +972-3-9230332 [email protected] Italy SILCA S.p.A. Via Podgora, 20 (Z.I.) Vittorio Veneto - TV 31029 +39-0438-9136 +39-0438-913800 [email protected] Japan Clover Co. Ltd 1-2-40 Haradanaka, Toyonaka-shi Osaka 561- 0807 +81-6-6844-2111 +81-6-6844-1147 [email protected]

Nairobi +254-20-6532913 +254-20-6533370 +254-20-6533369 [email protected] Kuwait Hasawi & Sabano Co. For Gen.Trad. P.O. Box 42105 Kuwait City 70652 +965-24832505 +965-2622778 [email protected] Latvia Solo F Ltd. Salaspils 12 Riga 1057 +371-7278359 +371-7876901 [email protected] Lebanon Mouawad Books & Stationary Sarl. Mouawad Str. Mouawad Center, 60094 Jal el Dib Beyrouth +961-4-711202 +961-4-11206 [email protected] Macedonia Panevski & Sinovi Llidenska , 11 Kumanovo 1300 +389-31-411545 +389-31-412411 [email protected] Malta Unimark Ltd. 32, Zerafa Str. Hmr 03 Marsa +356-21-231540 +356-241319 [email protected] Mexico Corporacion Cerrajera Alba Sa De Cv Circuito Gustavo BAZ, 16 Atizapan de Zaragoza Messico D.F. 52966 +52-55-53667200 +52-55-53667291 [email protected] Mozambique Davel Importacao Comercio e Servicos Rua Do Carmo NR.54 - 3° Solat Coimbra 3000 +351 239833858 +351 914506747 New Zealand Baber LSC Limited Unit 5, 6 Argus Place Auckland Glenfield 1310 +649-444-5117 +649-444-5119 [email protected] Nigeria Chilex Security Products Ltd. 12, Olowu Street P.O. Box 5153 Ikeja - Lagos +234-1-4965005 +234-1-4965005 [email protected] Norway Prodib Ab Montorgat 16 Eskilstuna 632 29 +46-16-168000 +46-16-145590 [email protected] Poland Dar-Mar ul. Napoleona, 17 Kobylka 05-230 +48-22-7710118 +48-22-7710118 [email protected] Poland Z.P.U.H. Expres Wojcieck Kowalczyk 32-447 Siepraw 795 Siepraw +48-1227-46365 +48-1227-46365 [email protected] Portugal Casa Das Chaves Da Falagueira Ltda Estrada Da Falagueira 5B Amadora 2701 +351-214936430 +351-214912403 [email protected] Portugal Luso Chav' Av. Rodrigues de Freitas, 199-A Porto 4000- 303 +351-22-5104702 +351-22-5361248 [email protected] Romania M&C Business S.r.l. 36, Badea Cartan Street 2nd District Bucharest 20064 +40-213118602 +40-212120155 [email protected] Russia Strazh 16/2, pt. Komsomolskiy Moscow 119021 +7 495 7083440 +7-495-7083292 Russia O.O.O. Peter Key Mihaylovsky Pereulok, 7b Saint Petersburg 198095 +7-812-2520241 +7-812-2523885 [email protected] Saudi Arabia Fahd Omar Bamashmous Est. P.O. Box 20919 Jeddah 21465 +966-2-6422588 +966-2-6447238 [email protected] Serbia Silkon D.O.O. 29, Novembra 70 Belgrade 11000 +381-11-2080200 +381-11-3290017 [email protected] Singapore Silca Soxxi Pte. Ltd. 21 Toh Guan Rd. East #01-12 Toh Guan Centre Singapore 608609 +65-6316-8100 +65-6316-4470 [email protected] Slovakia H&B Slovakia s.r.o. Ovsistske Nam. 1 Bratislava 85104 +421-2-6252-0032 +421-2-6252-0033 +421-2-6252-0034 [email protected] South Africa Sanlic International (Pty) Ltd. 46, Hulbert Street New Centre Johannesburg +27-11-4939717 +27-11-6831312 [email protected] Spain Silca Key Systems S.A. C/Santander 73/A Barcelona 08020 +34-93-4981400 +34-93-2788004 [email protected] Sweden Prodib Ab Montorgat 16 Eskilstuna 632 29 +46-16-168000 +46-16-145590 [email protected] Switzerland Robert Rieffel Ag Widenholzstrasse 8 Wallisellen 8304 +41-44-8773333 +41-44-8773322 [email protected] Syria Muheiddin Arabi Katbi P.O. Box 1322 Damascus +963-11-2212407 +963-11-2224588 +963-11-2224588 +963-11-3737001 Taiwan Global Tecspro Ltd. 11F-2 N.42-2 Lian Sheng St. Jhongho City Taipei +886-2-22494028 +886-2-22425735 [email protected] Turkey Kadiköy Anahtar San.Ve.Tic.Ltd.Sti. Osmanaja Mah.Nüzhet Efendi Sk.No.56 Kadiköy - Istanbul +90-216-4145254 +90-216-3475488 [email protected] U.A.E. Sabano Trading Co.Llc P.O. Box 32075 Dubai +971-4-2682400 +971-4-2622778 [email protected] Ukraine Service-Centre Kopir Segedskaya 12 Odessa 65009 +38-487-433196 +38-487-190777 [email protected] United Kingdom SILCA Ltd. 6 Lloyds Court Manor Royal Crawley RH10 9QU +44-1293-531134 +44-1293-531108 [email protected] U.S.A. Kaba Ilco Corp. 400 Jeffreys Road, P.O. Box 2627 Rocky Mount NC 27804 +1-252-446-3321 +1-252-446-4702 [email protected] Venezuela La Casa del Cerrajero C.A. Av. Principal de Maripérez Caracas +58-212-793-0083 +58-212-781-8692 [email protected] Yemen Sabano Trading Co.Llc P.O. Box 32075 Dubai U.A.E. +971-4-2682400 +971-4-2622778 [email protected]

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