Silca Rekord AY 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: February 2019 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.

2 WORKING PARTS ..........................................................................................6 3 MACHINE DESCRIPTION ...............................................................................7 3.1 Further Risks ........................................................................................8 3.2 Technical Data ......................................................................................8 3.3 Electric circuit .......................................................................................8 4 ACCESSORIES PROVIDED ...........................................................................9 5 MACHINE INSTALLATION and PREPARATION ........................................10 5.1 Checking for damage .........................................................................10 5.2 Environmental conditions ...................................................................10 5.3 Removing the blocks ..........................................................................10 5.4 Positioning ..........................................................................................10 5.5 Separate parts ....................................................................................11 5.6 Description of work station .................................................................11 5.7 Connection to the mains .....................................................................12 5.8 Graphics .............................................................................................12 6 MACHINE REGULATION AND UTILIZATION .............................................13 6.1 Checking and setting ..........................................................................13 6.2 Gauging ..............................................................................................13 7 CUTTING OPERATIONS ..............................................................................15 7.1 Key cutting ..........................................................................................15 7.2 Code key-cutting .................................................................................15 8 MAINTENANCE ............................................................................................16 8.1 Replacing the cutting tool ...................................................................16 8.2 Replacing the brush ............................................................................17 8.3 Replacing and/or tightening the belt ...................................................17 8.4 Replacing the tracer point ...................................................................18 8.5 Replacing the fuses ............................................................................19 8.6 Access to the lower part .....................................................................19 8.7 Replacing main switch ........................................................................20 8.8 Replacing motor/condenser ................................................................20 8.9 Replacing lamp feed (transformer) .....................................................21 8.10 Replacing lamp set/lamp protection ...................................................22 8.11 Replacing motor on switch .................................................................23 9 DISPOSAL .....................................................................................................24 10 ASSISTANCE ................................................................................................25 10.1 How to request service .......................................................................25

REKORD AY Copyright Silca 2019 3 GUIDE TO THE MANUAL This manual has been produced to serve as a guide for users of the REKORD AY 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) Tip 4) Cuts 2 1 3 4 NO

4 Copyright Silca 2019 GENERAL INTRODUCTIONS The REKORD AY 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 the 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 REKORD AY is a key-cutting machine and must be installed and used according to the rules and specifi cations established by the manufacturer. The key-cutting machine must be used only by skilled personnel (professional use). The key-cutting machine is designed for use on business or industrial premises (e.g. hardware shops, key cutting centers, etc...). This equipment should not be used where children may be present. Any other use different from that indicated in this manual will cause the forfeiture of all customers’ rights to make claims on Silca S.p.A. and may be an unknown source of hazard for the operator or third parties.. 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 AY 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 further risks arising from the use of the machine (see chap. 3.1, page 8). Protection and safety precautions for the operator The REKORD AY 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 adoption of general safety precautions (wearing protective goggles) and observation of the instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate. The REKORD AY 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 REKORD AY key-cutting machine is provided with an identification label which shows the serial number (fig. 2). Fig. 2 (*) see chap. 9 "DISPOSAL", page 24.

REKORD AY Copyright Silca 2019 5 1 TRANSPORT The REKORD AY key-cutting machine is easily transported and is not dangerous to handle. The packed machine can be carried by one person. 1.1 Packing The REKORD AY 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 AY 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 manufacturers for repairs or servicing). 4) check the contents of the box, which should comprise: - 1 REKORD AY 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 REKORD AY 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 2019 2 WORKING PARTS Fig. 4 A - coded angle device A1 - rotating centring clamp (position jaw) A2 - lower jaw A3 - tip stop A4 - coded angle device indicator A5 - coded spacing device drum B - rotating centring clamp knob C - clamp carriage C1 - chippings tray C2 - tool tray D - carriage lever handle E - coded spacing device E1 - axis regulation grub screw E2 - axis regulation locking screw F - coded spacing device knob G - tracer point G1 - tracer point locking grub screw G2 - centesimal ring H - cutter H1 - lamp J - brush J1 - brush cover M - top cover N - motor on switch O - main switch P - supply socket Q - protective pad S - motor U - fuses A1 A2 A4 A5 E1 E2 F A3 D A B C E G G1 G2 H J O S C1 C2 J1 M F H1 U P N Q

REKORD AY Copyright Silca 2019 7 3 MACHINE DESCRIPTION REKORD AY is a professional key-cutting machine for ABLOY keys. The machine comprises the following main parts: Main switch The key-cutting machine is connected to a power supply socket provided with a differential switch. Pressing the switch (O) powers 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 AY 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 (J) and cutting tool (H1). These components are protected by two covers: - protective belt cover (J1), - top cover (M). Mobile unit The mobile unit comprises a carriage (C) which holds a code space setting device and a clamp for securing the keys, with a code device for adjusting inclination (fig. 4, page 6). The carriage (C) is fitted to the translation shaft and is moved manually by the operator. It has been designed to avoid the accumulation of cutting dust or chippings. The key-cutting machine has an inclined table which allows the chippings to collect in the special tray (C1) placed under the carriage and easily removable for thorough cleaning. WORKING PARTS The working parts are described below: • Brush The brush (J) is used to eliminate burrs from the cuts and is made of non-abrasive material. • Cutting tool The cutting tool (H) is the part of the REKORD AY used for cutting key blanks. The cutting tool is in HSS super rapid steel and is protected by a special cover (M) to ensure safe operation. • Tracer point The tracer point (G) housed on the left-hand side of the machine base. A centesimal ring (G2) ensures regulation of the depth. • Coded angle device The device comprises: - a clamp (A1), connected directly to the inclination setting device, which acts as a key centring device and tip stop. - a jaw (A2) with which to secure the key, activated by knob (B). • Coded spacing device The code device comprises a knob (F) to activate a graduated slide which determines the position of the various cuts.

8 Copyright Silca 2019 3.1 Further Risks ATTENTION: there are residual hazards in the cutting zone (A) where the cutter is located. Carefully observe the warnings in the manual. • To fit or remove keys from the clamp STOP THE MOVEMENT OF THE CUTTER by means of the switch (N). If this is not done the carriage may cause a hazard by going unexpectedly towards the moving cutter. • After setting up the cutting code take care NOT TO MOVE your free hand towards the cutter zone (A). Fig. 5 3.2 Technical Data ELECTRICAL PROPERTIES: 230V - 50/60Hz 440W 2A CUTTING TOOL: HSS Super Rapid Steel MOTOR: One-speed single phase 230V - 50/60Hz; 1350/1620 rpm 0,18 Kw MOVEMENTS: manual CLAMP: rotating DIMENSIONS: width: 330mm - depth: 430mm - height: 270mm SONOROUS PRESSURE: Leq. = 83 dB WEIGHT: 18 kg. 3.3 Electric circuit The REKORD AY 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) The main parts of the electric circuit on the REKORD AY are listed below: 1) Main plug with fuses 2) Safety main switch 3) Illuminated switch 4) Motor: 230V a.c. 50/60Hz 5) Condenser 6) Feeder 7) 6 LED circuit board (lamp) A N black red Feeder (lamp) 6 LED circuit board brown light blue light blue brown yellow/green 1 2 3 6 4 7 5 ( ) ( ) (lamp)

REKORD AY Copyright Silca 2019 9 4 ACCESSORIES PROVIDED To ensure trouble-free working with the REKORD AY, 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 AY is supplied with a full range of accessories. The accessories provided by Silca are all that is necessary to carry out the operations for which the machine is designed. Fig. 6 C2 5X20 FUSES (2 pcs) 4 Amps rapid (230V) 2,5 mm ALLEN KEY 3 mm ALLEN KEY 19 mm SPANNER 10 mm SPANNER CUTTING TOOL UNCLAMPING PIN 4 mm ALLEN KEY 5 mm ALLEN KEY GAUGING CALLIPER

10 Copyright Silca 2019 5 MACHINE INSTALLATION AND PREPARATION The REKORD AY 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 AY 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 AY 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: da 0 a 40°C - relative humidity: 60% circa 5.3 Removing the blocks Remove the protective panel (1) between the carriage and the machine body and the blocks (2 and 3) between carriage and chippings tray (fig. 7). Fig. 7 5.4 Positioning Place the key-cutting machine on a horizontal surface, solid enough to take the weight (18 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 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. 8 2 1 3 200 mm 200 mm 200 mm

REKORD AY Copyright Silca 2019 11 5.5 Separate parts The separately packed parts must be installed on the REKORD AY key-cutting machine by the purchaser, as follows: Connection wire Connect the key-cutting machine power cable to the electricity mains (fig. 9). Fig. 9 Carriage lever handle Screw the handle (D) onto the carriage lever (fig. 10). Fig. 10 5.6 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 handle lever (D). Fig. 11 power cable electricity supply D D O N

12 Copyright Silca 2019 5.7 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. 5.8 Graphics THE USE OF PROTECTIVE GOGGLES IS COMPULSORY MOTOR SERVICE LABEL MASS-RPM-FUSIBLES LABEL

REKORD AY Copyright Silca 2019 13 6 MACHINE REGULATION AND UTILIZATION 6.1 Checking and setting The cutting tool on the REKORD AY is the part 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. Fig. 12 6.2 Gauging The REKORD AY key-cutting machine requires two types of calibration: axis and depth. Axial gauging Axial gauging is regulation of the position of the cutting spaces (fig. 12 - A). Axial gauging regulation To regulate the axial gauging, proceed as follows: ATTENTION: disconnect the machine from the mains. 1) set up the coded spacing device (fig. 13) by means of the knob (F) so that the indicator "5" is aligned with position "2”. 2) place the gauging calliper provided in the clamp (A1) (fig. 14), pushing towards the side of the tip stop (A3), and secure by turning the knob (B). 3) take the carriage towards the cutting tool and place the tracer point (G) all the way into the locating groove (E3) (fig. 15, page 14). 4) check that the cutting tool enters clearly into the groove in the gauging calliper. If adjustment is necessary, loosen screw (E2) and adjust axial gauging by means of the grub screw (E1) (fig. 13). 5) when gauging is complete, tighten the screw (E2) well. Fig. 13 Fig. 14 A B view from the tip E3 Q F E2 E1 Q1 gauging caliper groove A3 B A1

14 Copyright Silca 2019 Depth setting Depth setting is regulation of the cutting depth (fig. 12 - B). Usually depth setting is not necessary during normal use of the machine. However, if the tracer point is replaced or an optional carriage is used it is advisable to check the depth settings. Regulating depth setting To regulate the depth settings, proceed as follows: ATTENTION: disconnect the machine from the mains. 1) set up the coded spacing device by means of the knob (F) so that the indicator "5" is aligned with position "2" (fig. 13, page 13). 2) insert the tip of the gauging calliper (provided) into the rotating clamp (A1) (fig. 14), push up against the tip stop (A3) and lock in the calliper by turning the knob (B). 3) take the carriage towards the cutting tool and place the tracer point (G) all the way into the locating groove (E3) (fig. 15). 4) check that the cutting tool enters clearly into the groove in the gauging calliper (fig. 15). If adjustment is necessary, adjust axial gauging in the way described above ("Axial gauging regulation"). 5) loosen the screw (G1) locking the tracer point (fig. 16). 6) use the lateral brush (J) to turn the cutting tool shaft in the opposite direction to cutting. The cutting tool should skim the bottom of the groove on the gauging calliper. If not, turn the ring nut (G2) (fig. 16) clockwise to move the cutting tool unit forward, or in the opposite direction to move it back. 7) when the ideal regulation has been reached, tighten the tracer point locking screw. 8) if an optional carriage is used, check that the tracer point enters freely into the locating groove (E3) and that there is not excessive play on it. If necessary, adjust play between the locating groove and tracer point by loosening the nut (Q) and turning grub screw (Q1) (fig. 13). When adjustment is complete, tighten the nut (Q). Fig. 15 Fig. 16 G2 G1 G

REKORD AY Copyright Silca 2019 15 7 CUTTING OPERATIONS ATTENTION: to work in complete safety, pay special attention to the following recommendations: • Always work with dry hands. • Check that the machine is properly earthed. • Use the protective goggles, even if the cutting tool is fitted with a protective shield. • Start the motor only when all the operations with the carriage have been carried out (securing keys, etc.). • Keep hands away from the cutting tool when in motion. 7.1 Key cutting Placing keys into clamp Place the key blank into the clamp, pushing against the side of the tip stop (A3) and secure by turning the knob (B) (fig. 17). Fig. 17 7.2 Code key-cutting Important note:ABLOY keys can feature two types of cut which differ only in the distance between the first cut and the tip of the key. This distance can be 3 or 5 mm (fig. 12-A). To cut keys with 3 mm use mark 3 on the locator (fig. 13) as a reference for positioning the key. For 5 mm keys, use mark 5 (fig. 13). To code cut a key blank proceed as follows: 1) set the cutting position on the space code device by means of knob (E1) (fig. 17). Exert pressure on knob (B) to turn the rotating clamp (A1) until the code for the inclinations marked on the drum (A5) is aligned with the indicator (A4). 2) activate the machine by pressing the motor/brush start switch (N) (fig. 4, page 6). 3) move the carriage towards the cutting tool, making sure that the tracer point slides right into the notch on the locator (fig. 17). Make the cut and pull back the carriage. 4) go on to the following position and repeat the cutting operation with the corresponding code, and so on until the key has been cut. 5) pull the carriage back, turn off the machine, loosen the clamp (A1) and remove the key. A3 B locator E1 A4 A5 key blank B A1

16 Copyright Silca 2019 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 AY 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.). 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: turn off the machine and disconnect the supply wire. 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 tighten loosen

REKORD AY Copyright Silca 2019 17 8.2 Replacing the brush When the brush no longer cleans off the burrs it must be replaced as follows: ATTENTION: turn off the machine and disconnect the supply wire. 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 must be replaced or adjusted so as to ensure safe and proper operation of the cutting tool/ brush. Tension: ATTENTION: turn off the machine and disconnect the supply wire. 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 tension is obtained. 5) Tighten the four screws. Fig. 20 Replacement: ATTENTION: turn off the machine and disconnect the supply wire. 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. 21) 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 rod brush holding screw tighten loosen M1 M2

18 Copyright Silca 2019 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 (G) (fig. 25), proceed as follows: ATTENTION: turn off the machine and disconnect the supply wire. 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 (G1). 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 (G1). 8) Tighten the screw (K1). 9) Re-set the machine as described in chap. 6, page 13. Fig. 24 Fig. 25 S S1 P2 P1 K1 G2 G1 G

REKORD AY Copyright Silca 2019 19 8.5 Replacing the fuses ATTENTION: turn off the machine and disconnect the supply wire. 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 (P). 4) Replace the fuses (U) (fig. 26). 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). Fig. 26 8.6 Access to the lower part ATTENTION: turn off the machine and disconnect the supply wire. 1) Detach the wire from the key-cutting machine socket. 2) Remove the double box (tool holder/swarf tray) (C2) and (C1). 3) Turn the machine over onto its back. 4) Loosen the 6 screws (Y) to remove the bottom grate. Fig. 27 fuse box U P Y

20 Copyright Silca 2019 8.7 Replacing main switch ATTENTION: turn off the machine and disconnect the supply wire. 1) Access the bottom part (see ch. 8.6). 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. 27). 7) Turn the machine back into place on the work bench. Fig. 28 8.8 Replacing motor/condenser ATTENTION: turn off the machine and disconnect the supply wire. Motor 1) Remove the two protective pads (Q). 2) Loosen the 3 screws (M1) and remove the top cover (M) (fig., page 17). 3) Detach the 4 connectors (S2) from the motor on 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. 29 Condenser - Access the bottom part (see ch. 8.6) - Remove the motor (see ch. 8.8 - Replacing motor) - Loosen the nut (Z) (fig. 31) 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 condenser, 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 fixing plate with the screw (S3). - Replace the motor. Fig. 30 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. 29) to the motor on switch and fit the earth wire to its screw with the nut (S5) (fig. 33). 9) Replace the condenser and secure with washer and nut. 10) Replace the bottom grate and secure with the screws (Y) (fig. 27). 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). Y1 S2 S3

REKORD AY Copyright Silca 2019 21 Fig. 31 Fig. 32 Fig. 33 8.9 Replacing lamp feed (transformer) ATTENTION: turn off the machine and disconnect the supply wire. 1) Access the bottom part (see ch. 8.6). 2) Loosen the 2 low voltage connector screws (Q1) remove and place in their seat on the new transformer, 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.27, page 19). 7) Place the machine in position on the work bench. Fig. 34 Fig. 35 Z X X1 S4 S5 Q1 Q3 Q2

22 Copyright Silca 2019 8.10 Replacing lamp set/lamp protection Lamp set ATTENTION: turn off the machine and disconnect the supply wire. 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. 8.6). 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. 27). 11) Place the machine in position on the work bench. Lamp protection ATTENTION: turn off the machine and disconnect the supply wire. 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 towards the bottom of the machine. 7) Replace the top cover and secure with the 3 screws (M1). Fig. 36 Fig. 37 L1 L2 L3

REKORD AY Copyright Silca 2019 23 8.11 Replacing motor on switch ATTENTION: turn off the machine and disconnect the supply wire. 1) Access the bottom part (see ch. 8.6). 2) Detach the 4 connectors (S2) (fig. 38) 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. 27). 6) Place the machine upright on the work bench. Fig. 38 S2

24 Copyright Silca 2019 9 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.

REKORD AY Copyright Silca 2019 25 10 ASSISTANCE Silca provides full assistance to purchasers of the REKORD AY 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 addresses of specialised Service Centres. 10.1 How to request service The guarantee attached to REKORD AY key-cutting machines ensures free repairs or replacements of faulty parts within 12 months of purchase. All other service calls must be arranged by the customer with Silca or with a Silca service centre.

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 models REKORD REKORD AY REKORD SOFER REKORD S REKORD D12 comply with the requirements of the following European Directives: European Union DIRECTIVE 2006/42/EC (Machines) European Union DIRECTIVE 2014/30/EU (Electromagnetic Compatibility) European Union DIRECTIVE 2014/35/EU (Low Voltage) European Union DIRECTIVE 2011/65/EU (RoHS2) European Union DIRECTIVE 2012/19/EU (WEEE) | 18 | and with the following Standards: EN 55032:2015 + AC:2016 IEC TR 62778:2014 EN 55024:2010 + A1:2015 EN 62471:2008 EN 61000-3-2:2014 EN 62368-1:2014 + EC:2015 + A11:2017 EN 61000-3-3:2013 EN ISO 12100:2010 EN 62233:2008 EN ISO 13849-1:2015 EN ISO 13849-2:2012 Silca S.p.A. R&D Division is authorized to create a Technical File. VITTORIO VENETO, 15/05/2018