2934A-NOVA Quick Start Guide
Contents
1. Nova 2000 a i SUPPLEMENTAL OPERATION MANUAL T 7 EEN This manual applies specifically to the Nova 2000 Key Machine It properly iden tifies your model and assures you will receive correct parts if and when you require replacement parts Retain this manual in a safe place If ownership of this machine is transferred this booklet should accompany the machine W hen seek ing service information about this machine refer to the M odel No which is Nova 2000 and the part number desired see pages 5 7 CONTENTS EEN ER ch tae we ee Ak k eee A ee ee 2 General Safety se Gin ik 45 dae ee ce ee ee S Sa de 3 Introduction U npacking Instructions 2 0000 cee eee 4 Operating Parts Identification Names and Part Numbers 5 Parts H aciu duksas teen teehee eee eee ahead iais teed eee ee 6 7 Exploded View electrical 0 cee eee 7 Basic Operation 8 Adjustment of Cutter and Cutter Guide nauau is 9 Key Duplication Procedures 0 cee ee 10 11 Table 1 and Optional Accessories L LL kaka es 12 ONE YEAR LIMITED WARRANTY Kaba Ilco Corp warrants to the original buyer of any new model Nova 2000 machine that it will repair or replace at its option any part of any machine which proves to the reasonable satisfaction of Kaba Ilco Corp to have defects arising from the faulty manufacture of the machine or from defective material or components during a period of one 1 year from the date of the shipment of the mach2. EXPLODED VIEW MECHANICAL M327010 MK260306 M327003C8 gt MKZ60303 M327004 MK260317 C10026 M07542023 M07542001 MS200356 Fig 2 Nova 2000 Supplemental Operation Manual EXPLODED VIEW ELECTRICAL Ee MK260063 I M07542014 M07542013 Tt A AA i T i Tit Vell O CH CH U LA AA H U a MO7542024 M32700265 i MO7542012 Uf p M327023C6 S ad i UZ le K206135C5 1 L DG MS200348 gt TL M327021 Le A M07542011 T E sae MK206135C5 ab C20003 2 D M327034 d ww M323017C5 N C20034 A M327020 J G 2 M327012 BS OKO e M327806V8 M327017 K V el A S i 1 SR216019C5 S M327022CB M323091C5 M327015 M327013 J K S SS SR216018C5 L 2 M327009 C20044 aw 4327027 N M327005C6 M327008C6 za ja CN Ta A Nova 2000 Supplemental Operation Manual BASIC OPERATION The Nova 2000 is designed to duplicate various types of high security keys As shipped this versatile machine duplicates sidewinder style automotive keys aS well as several dimple types Optional cutters and acces sories are available that will broaden the range of keys that the Nova 2000 can duplicate see page 12 Dimple Keys Sidewinder Keys Three basic steps should occur before the
3. built into the machine Removal or modifica tion of safety shields cutter guards and other safety devices should be strictly forbidden s At no time should the mechanically driven parts of the machine be touched while it is in operation Extra care should also be taken by the Operator to ensure that loose fitting clothing long hair etc are kept from the area of machine operation e Your machine has been specifically designed and built for key cutting purposes only and should be operated according to its operator s manual All other uses are strongly discouraged as they could be potentially hazardous and should not be attempted Such use will immediately void the machine warranty e Some states have specific age restrictions concerning the operation of cer tain types of equipment Check local and state ordinances for compliance Electrical Safety e 120 volt models Your machine is designed to operate using 120 Volt AC 60 Hz electrical current It is supplied with a three prong power plug which should be used with a properly grounded three prong outlet only Do not defeat the safety purpose of the plug by modifying or using with non grounded outlets e To reduce risk of fire or electrical shock do not expose or operate machine in damp or wet locations Electrical problems should be referred to qualified repair technicians If the machine is under warrant contact Kaba Ilco Corp Kaba Ilco Corp also offers repair service for out of
4. produce consistently accurate duplicate keys EE Nova 2000 Supplemental Operation Manual 9 KEY DUPLICATION PROCEDURES Gauging Once the appropriate key blank has been selected and the depth calibration verified the only step remaining before actually duplicating the key is to clamp and gauge the pat tern key and key blank Gauging is simply the process of positioning both keys to insure that the cut pattern on the original key is copied onto the key blank at the proper location There are two general types of keys which can be duplicated on the Nova 2000 shoul der gauged keys and tip gauged keys These terms refer to the method by which a key is correctly oriented within a lock cylinder rel ative to its pins or tumblers They are clamped into the Nova 2000 vise jaws using different techniques Shoulder Gauged Keys See Fig 6 Keys that have a distinct square shoulder such as the S48HF P These keys are positioned in the vise so that their shoulder surface is in contact with the front edge of the vise jaws when the Example of Shoulder clamp knob is tightened See Fig 8 SE E 6 Key L gt Example of Tip Gauged Key Fig
5. to save the original packing carton for later shipment if necessary Place the key machine on a sturdy level work bench with good lighting The 115 VAC receptacle should be properly grounded Do not use a two prong plug adapter Unpack all cutters key guides and adapters Wipe each part free of grease and oil Be sure to keep all operating parts as free as possible from cutting debris to maintain trouble free operation Store accessories in an organized manner pro tecting them from damage or loss It is strongly recommended that this manual be thoroughly read by anyone who plans to operate the Nova 2000 Fig 1 should be studied in order to learn the gen eral operating parts of the machine and their nomenclature CAUTION DO NOT DESTROY OR DISCARD THE SHIPPING CAR TON STORE IT CAREFULLY IN A SAFE PLACE IN THE EVENT OF A PROBLEM WITH YOUR MACHINE IT SHOULD BE RETURNED TO OUR SERVICE FACILITY IN ITS ORIGINAL PROTECTIVE CARTON REESEN 4 Nova 2000 Supplemental Operation Manual OPERATING PARTS IDENTIFICATION Ref Description Ref Description Cutter Guide Locking Screw On Off Switch Cutter Locking Screw Spring Mechanism Control Knob Right Lever Depth Adjusting Knob N Left Vise Jaw Clamping Knob Depth Adjustment Locking Knob L t Vise Assembly Locking Knob Carriage M ovement Lever P Carriage Locking Knob Vertical M ovement Locking Knob Nova 2000 Supplemental Operation M anual 5
6. warranty machines Contact for details e Always unplug the machine before opening the hood or changing the cutter i TTT T T ii Nova 2000 Supplemental Operation Manual 3 G INTRODUCTION The Nova 2000 is a precision engineered key machine specifically designed for duplicating high security type keys As shipped the Nova 2000 will efficiently duplicate high security centerwinder and sidewinder automotive keys as used by Mercedes Benz Saab Volvo and others as well as keys that fit various dim ple key lock systems A wide variety of optional adapters and cutters are also available that enable the Nova 2000 to duplicate keys for an even broader range of high security lock products This unique key machine has the ability to duplicate keys to exacting specifica tions resulting from the precise accuracy of its many parts The Nova 2000 was designed with the operator in mind from the versatility of the vise jaws to the easy one handed operation of the machine Because of the precision nature of the vise jaws avoid any abuse that will damage or reduce their accuracy Treat them with care and the jaws will help produce accu rate keys for years UNPACKING INSTRUCTIONS When unpacking the Nova 2000 you will note the cushioning material and the abundance of lubricating oils to prevent rust and corrosion Before using this machine wipe off excess grease and oil Lubricate only the moving parts It is a good idea
7. 7 Tip Gauged Keys See Fig 7 Keys that have no shoulder or the shoulder is not square to the key blank S32 Y S P SSOHF P etc are gauged using the tip of the key as the ref erence point Locate the tip stop bars Fig 10 into the slots on the vise jaws as shown butt the tip of both keys against the tip stop bars and tighten the clamp knobs Remove the tip stop bars prior to cutting the key See Fig 9 Shoulder contacts front edge of vise jaw Tip Stop Bars D402302BA Fig 10 10 Nova 2000 Supplemental Operation M anual E KEY DUPLICATION PROCEDURES Duplication Procedure NOTE Always wear safety glasses or goggles when operating the Nova 2000 or any other key cutting device Only the duplication procedure for sidewinder high security auto keys will be covered in this example Information regarding the duplication of dimple keys can be found in the pri mary manual accompanying the machine Reminder Do not use this machine for any pur pose other than duplicating high security keys because of risk of injury and machine dam age Such use will immediately void the machine warranty One Hand Operation Sidewinder type keys may easily be cut with the use of the car riage movement handle only by pre setting the depth First load and gauge the original key in the left vise jaw in preparation for cutting Do not load the blank key yet Lower the Cutter Guide using the Vertical M ovement Lev
8. any other warranty of condition expressed or implied including without limitation merchantability fitness for a particular purpose or latent defect The buyer releases Kaba Ilco Corp from any liability for any reason other than a breach of its warranties hereunder The liability of Kaba Ilco Corp shall in no case including negligence exceed the purchase price of the defective machine nor shall Kaba Ilco Corp be liable for any personal injuries property damage or con sequential damages Use only genuine Kaba Ilco Corp replacement parts on this machine cg 2 Nova 2000 Supplemental Operation Manual WARNING SAFETY NOTICE IMPORTANT PLEASE READ CAREFULLY BEFORE OPERATING MACHINE Safety begins with education and continues with proper application ALL per sonnel who operate this machine should READ THE SUPPLIED OPERATOR S MANUAL for information on how to properly operate the Nova 2000 The like lihood of accidents and miscuts will be greatly reduced General Safety e Safety glasses MUST BE WORN to reduce the possibility of eye injury while operating or in the immediate vicinity of key cutting equipment Always turn machine off before making adjustment or inserting or removing keys e Machine should be located in an area accessible only by authorized oper ators Location must be such that customers and other personnel are not Subject to potential injury from flying chips e Do not defeat safety features
9. duplication process actually begins 1 Key Blank Selection The key blank selected must be correct for the intended appli cation 2 Cutter Cutter Guide Selection The cutter and corresponding cutter guide installed on the Nova 2000 must be correct for the type key being cut See chart on page 12 3 Positioning of the Key Blank and Pattern Key Also referred to as gauging this process involves inserting the blank and pattern keys into the machine vise jaws in a manner that assures proper placement of cuts on the blank during the duplication process Installing Cutter and Cutter Guide Note Always be sure that the machine power is off before installing or changing cutters The cutter and cutter guide must match in order to cutter accurate keys Refer to table 1 at the back of this booklet for matching cutter guide numbers and applications After selecting the cutter and guide required for the intended application install them as shown in figure 4 below by positioning them as far as they will go into their correspon ding chucks and tightening set screws L and H Note The machine s depth of cut adjustment must be reset each time a cutter or cutter guide is installed on the machine 8 Nova 2000 Supplemental Operation M anual ADJUSTMENT OF CUTTER AND CUTTER GUIDE Periodically check the machine s depth adjustment and recalibrate if necessary to compensate for possible cutter wear In addition as p
10. er until it touches the cut surface of the original key Fig 11 While holding this depth tighten the Depth Locking Knob firmly The blank key may now be loaded gauged and cut without further adjustments to the Vertical M ovement Lever With both keys loaded and properly gauged lower the chip Shield into position and switch on the cutter motor Using the Carriage Movement Lever position the vise containing the pat tern key so that the cutter guide enters into the cuts on the key Paying attention to the pattern key trace the cutter guide against the cuts on the key The feel of the cutting action Is similar to using a router operators quickly learn the most efficient direction of cut to use for various key types A steady even cutting pressure should be used do not apply excessive force After the cuts on one side of the pattern key have been traced remove the half completed key blank and flip it over to the other side and repeat the cutting process Key Cutting Tips The following are a few pointers that will make your key duplicating efforts more productive 1 Operate the Nova 2000 In a well lit reasonably clean work area 2 Replace the cutter on the machine when it starts to get dull Symptoms include vis ible burrs on the duplicate keys produced greater noise and noticeably more pres Sure required to cut them 3 Keep a spare cutter on hand for the machine the slight expense Is small compared to the potent
11. ial lost sales you could experience awaiting a replacement 4 Keep a small brush near the Nova 2000 at all times Don t allow key shavings to accumulate on the machine brushing the vise jaws off after every couple of keys is very important and can help prevent miscuts 5 Maintain the machine properly LUBRICATION POINTS are explained in the accompanying bound manual a ee Nova 2000 Supplemental Operation M anual 11 TABLE 1 Application 3 mm tip diameter y mm tip diameter CT BM W Mercedes Benz Infiniti CU56 048 KD56 047 Saab Honda VW Audi 260048 260047 17 Angle 65mm flat 5 Angle 65mm flat q Keso Sargent Keso Dom CU56 043 KD56 044 BMW dimple type 260043 260044 2 5 mm tip diameter F mm tip diameter Lexus Required BMW Mercedes Benz Volvo init fe F22 optional item except T22 optional item except Infi nit Saab Honda VW Audi with Lexus with Lexus Optional OPTIONAL ACCESSORIES T Tom PartNo Description _ Volkswagen D711803ZB Pair of Adapters will allow Audi the user to cut keys with Porsche internal cuts Jaguar D707657ZB Code attachment Reguired Tibbe to create a key by code 8 cuts and 3 angles D708005ZB Decoder Will reconstruct and identify the depth of cuts on a key For 8 cut 3 angle version Ford Jaguar D705485ZB Code Attachment Required Tibbe to create a key by code 6 cu
12. ine by Kaba Ilco Corp provided that the machine is returned by prepaid transport to Kaba Ilco Corp or to its authorized representative before the expiry of the warranty period together with a detailed description of the alleged defect s Kaba Ilco Corp may at its discretion elect to refund the purchase price allocable to the part affected or to issue a credit if the price therefore remains unpaid Kaba Ilco Corp sells precision made machines The buyer assumes all risks and Kaba Ilco Corp shall not be liable for any reason if the machine has been subjected to improper installation improper use improper or inadequate maintenance negligence if any unauthorized modification or alteration is made to the machine or in case of accident For greater certainty any machine not operated in accordance with Kaba Ilco Corp printed instructions or operated beyond its rated capacity shall not be covered by this or any other warranty Any and all warranties made by Kaba Ilco Corp on any machine product or component thereof shall be effective only if and for so long as the buyer complies with all payment obligations pursuant to the buyer s accepted and acknowledged order Failure to meet such payment obligations shall void all warranties and not extend the period of time for which such machine product or component thereof is warranted irre spective of whether or not payment is eventually made These warranties are in lieu of and notin addition to
13. reviously stated the depth adjustment must be reset anytime a cutter or cutter guide is installed on the machine Depth Adjustment Perform steps 1 4 with power off L E Verify the vise jaw clamping surfaces are free of dust and chip debris gener ated from cutting keys Insert two key blanks must be same type into the Machines vise jaws Confirm they are posi tioned flat and level within the jaw Tighten the clamping knob on each jaw as this is done Pull the Vertical Movement Lever M see page 5 for part iden tification towards you to allow the cutter and guide to contact the two blanks Fig 5 Loosen locking knob G if required Loosen the Depth Adjustment Locking Knob E and rotate the Depth Adjusting Knob D left or right as required until the cutter end guide con tact both key blanks at the same time Once this step is accomplished tight en the Spring M echanism Control Knob C to assure that it wasn t loosened during the previous procedure Check the final adjustment by turning the power and cutter motor switch on lower the cutter to the flat surface of the blank using the Vertical Movement Lever M The cutter should barely graze the surface of the blank pro ducing only a light swirl on the surface If the cutter contact appears excessive or there isn t any contact at all turn off the power switch and repeat step 4 This adjustment must be properly set to
14. ts and 4 angles Ford Jaguar D705322ZB Decoder Will reconstruct Tibbe andidentify the depth of cuts on a key 6 cut 3 angle version Kaba Ilco Corp August 2001 12 Nova 2000 Supplemental Operation M anual
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