045 HD manual
Contents
1. EXPLODED VIEW EXPLODED VIEW EXPLODED VIEW PARTS LIST Refer to pages 6 7 for illustration Ref Part no Description Ref Part no Description 1 045HD 1 Carriage 79 024B 79 Key gauge spring 1X 045HD 1X Carriage assembly 84 024B 84 Clip 2 025 2 Carriage stud 86X 045HD 86X Safety hood assembly 3X 045HD 3X Vise jaw assembly Super Jaw 3 87 045HD 87 Safety shield 4 025 4 Vise jaw spring 89 045 89 10 Lockwasher 6X 025 6X Thrust bearing set 90 1025 90 Nut 10 32 8 1025 8 Wing nut 91 024B 91 Power cord 9X 040 9X Carriage handle 92 024B 92 3 wire motor cable 20 040HD 20 Cutter shaft bearings 100 040HD 100 Cutter spacer right 21 025 21 Carriage shaft bushing 101 025 101 Motor pulley set screw 23 045HD 23 Carriage shaft 106 040 106 Chip tray 32 024B 32 Button head screw 10 24 x 109 025 109 Bearing washer 36 025 36 Cutter nut N 4 110 025 110 Wave washer 37 025 37 Cutter spacer left 129 040 129 Locking nut 8 32 38 P X23MC P X23MC cutter 146 040 146 Power cord strain relief 40 040HD 40 Cutter shaft 150 040 150 Switch screw 6 32 x 1 4 41 025 41 Cutter shaft pulley 151 040 151 Set screw 8 32 x 3 8 43 814 00 51 Nylon brush 160 025 160 Caution label 45 024 45 Brush bolt washer s 163 045 163 Hood Screw 46A 025 46A Hex head screw e 18 x 171 025 171 Cutter pulley set screw 18 47 025 47 M2. It is not intended or designed for any other purpose The machine operator assumes all liabili ty when using this machine in a manner inconsistent with its stated design purpose Refer to page 3 for complete safety information before operating the machine KABA ILCO strongly recommends the use of protective eye glasses or goggles when operating this machine or CAUTION when in the vicinity of the machine while it is being oper ated Protective eye wear prevents injuries The machine should be turned off before loading or unloading keys When the key machine is operating be careful not to contact the vise jaw or carriage against the cutting wheel as this will cause damage to the cutter jaw or carriage DO NOT DESTROY OR DISCARD THIS SPECIAL SHIPPING CARTON STORE IT CAREFULLY IN A SAFE PLACE THIS CARTON SHOULD BE USED WHENEVER THE MACHINE IS MOVED OR SHIPPED OPERATING PARTS Key gauge Safety hood assembly Safety shield Depth Dial Nylon brush Cutter g Ude Wing nut Carriage Carriage shaft On Off power switch Vise jaw assembly Operating parts identification Part no Identification 024B 1 Carriage 025 3X Vise jaw assembly 025 8 Wing nut 045 23 Carriage shaft P X23MC P X23MC cutter 814 00 51 Nylon brush 045 49 Cutter guide stylus 045 55A Adjusting screw 040 56 Key gauge 025 62A On Off switch 045 86X Safety hood assembly 045 87 Safety shield
3. ILCO to have defects arising from the faulty manufacture of the machine or from defective material or compo nents during a period of one 1 year from the date of shipment of the machine by KABA ILCO provid ed that the machine is returned by prepaid transport to KABA ILCO or to its authorized representative before the expiry of the warranty period together with a detailed description of the alleged defect s KABA ILCO may at its discretion elect to refund the purchase price allowable to the part affected or to issue a credit if the price therefore remains unpaid KABA ILCO sells precision made machines The buyer assumes all risks and KABA ILCO shall not be liable for any reason if the machine has been sub jected 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 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 on any machine product or component thereof shall be effec tive only if and for so long as the buyer complies with all payment obligations pursuant to the buyer s accept ed and acknowledged order Failure to meet such pay ment obligations shall void all warranties and not extend the period of time for which s
4. key should be tilted 2 Do NOT use pliers or other tools to tighten the vise jaws Firm hand pressure is sufficient 3 Keep the carriage shaft free of metal chips A thin film of oil can be applied to it The carriage should be free to move without binding 4 NEVER touch the shoulder of a key to the side of the cutter guide This will cause the shoulder of the key blank to touch the side of the cutting wheel When this happens some of the metal will be cut away from the shoulder of the key blank If the resulting dupli cated key is duplicated two three four times over an error will accumulate and cause a non operating key Do not grind away the shoulder 5 Don t run the cutter into the vise jaw this will dull the cutter and reduce cutter efficiency 6 Keep the cutter clean Don t let any foreign objects or instruments blunt it This cutter is a precise cutting tool and should be handled with care 7 Lubrication requirements for your new HD Performance Series key machine are minimized through the use of sealed permanently lubricated cutter spindle bearings The carriage shaft however should be inspect ed on a routine basis and wiped with a dry clean cloth to remove any chip buildup that occurs After cleaning application of a dry film lubricant is recommended for maximum service life spray type lubricants that dry completely once applied are fine Depending on usage the machine s 1 4 hp motor may require lubricati
5. thread and turns downward to loosen Remove the spacer washers and the dull cutter Install the new cutter the washers and the nut Adjusting for depth of cut To ensure safety UNPLUG machine from its power source before adjusting for depth of cut It s imperative that the key guide and the cutter be in the same plane that is aligned to each other If the cutter guide protrudes further than the cutter the resulting cuts in a key blank will be too shallow and the duplicate key will not work Likewise if the cutter guide is behind the cutter the cuts in the key will be too deep see Fig 6 Figure 6 Adjustment is correct when both key blanks touch To check the depth adjustment insert two identical key blanks into the vise jaws setting them flat in each vise It is not necessary to align the blanks Then raise the carriage positioning the left blank against the cutter guide and the right blank against the cutter Next turn the machine pulley by hand and note the right key blank The cutter should just barely graze the key blank when the adjustment is correct No cutter is perfectly round so make one complete rota tion of the cutter before changing adjustment There will Figure 7 Binding screw Depth Adjustment Carriage stop Dial adjusting screw ADJUSTMENTS be a high point on the cutter the adjustment should be made to the high point If the cutter does no
6. 045 HD INSTRUCTION MANUAL IMPORTANT Read these instructions before you use your new 045 HD Key Machine Ensure that all safety recommendations are followed See page 3 for instructions ERFORMANCE CUCI o A Member of the Kaba Group JS This manual applies specifically to the 045 HD When seeking service information about this machine Performance Series key machine It properly identifies your refer to Model No 045 HD and the part number desired model and assures you will receive correct parts if and see pages 6 to 8 Note that many parts are not inter when you require replacement parts Retain this manual in a safe place If ownership of this machine is transferred this service manual should accompany the machine changeable with other ILCO machines CONTENTS Warranty nennen Safety information 1 1111 Introduction unpacking Operating parts illustrated Operating parts identification names and part numbers 5 Exploded view ana nalen 6 Exploded view parts list unpacking test keys 8 How to duplicate Keys setts oc faa RAWA lac 9 The cutting operation replacing the cutter 111111111 12 AdjGSTMENES eseni A EREN E Jai 13 ONE YEAR LIMITED WARRANTY KABA ILCO warrants to the original buyer of any new model 045 HD machine that it will repair or replace at its option any part of any machine which proves to the reasonable satisfaction of KABA
7. ality inspectors work before approving your machine for shipment The keys are reproductions of fac tory dimensioned pattern keys and are accurate to 002 or less Save these keys and use them as standards to check the accuracy of cuts in the keys you make Duplicating a key and then using a key micrometer or caliper to compare the actual depth of the cuts on both the duplicate and the pattern key will allow you to see if your machine is cutting too deep or too shallow thus indicating that an adjust ment of the cutter guide is necessary Proper key cutting techniques Even though your 045 HD key machine is designed to make key cutting fast efficient and accurate operator skill is important The actual mechanics of placing keys within the vise jaws is simple to learn but there are some basics that must be followed A properly adjusted key machine used by someone who ignores good key cutting techniques will NOT produce a good key The way a per son clamps a key into the vise jaws is critical to the accu racy of the duplicated key Remember the real purpose of a duplicate key is to operate the lock for which it was intended If customers return keys you should reexamine your cutting tech niques and adjustment of the machine Here are some important operating tips 1 Vise jaws clean them regularly so that no metal chips lie under the keys It is essential that both keys lie flat across the entire width of each vise jaw Neither
8. d other personnel are not subject to potential injury from flying chips Do not defeat safety features built into your machine Removal or modification of safety shields cutter guards and other safety devices should be strictly for bidden Electrical safety 115 Volt models Your machine is designed to oper ate using 120 Volt A C 60 Hz electrical current It is supplied with a three prong power plug which should be used with a properly grounded three prong outlet only Do not defeat the safety purpose of the plug by modifying or using with non grounded outlets To reduce risk of fire or electrical shock do not expose or operate machine in damp or wet locations Grounding instructions In the event of a malfunction or breakdown ground ing provides a path of least resistance for electric cur rent to reduce the risk of electric shock This machine is equipped with an electric cord that has an equip ment grounding conductor and a grounding plug The plug must be plugged into a machine outlet that is properly installed and grounded in accordance with all local codes and ordinances Do not modify the plug provided if it will not fit the outlet have the proper outlet installed by a qualified electrician Improper connection of the equipment grounding conductor can result in a risk of electric shock The conductor with insulation that has a green outer At no time should the mechanically driven parts of the machine be to
9. e sided key which do not have a conventional shoulder the tip of the key is used as the aligning point see Fig 4 Clamp the blank key in first and move the machine carriage to the left Lower the key gauge and position the carriage so the tip of the Ford key touches the key gauge Install and align the pattern key in the left vise jaw in the same manner Figure 4 Recessed tip Use of gauge with various key types Best and Falcon type keys do not have a conven tional shoulder but have a recessed tip and the key gauge is used to align the recessed tips After clamping the blank key the carriage is moved to the left so that the key gauge can be lowered to contact the recessed tip sur face The pattern key is aligned in the left vise jaw and positioned to contact the edge of the key gauge in the same manner 11 THE CUTTING OPERATION REPLACING THE CUTTER General Operating Sequence WARNING Do not install or remove keys unless the off on switch is in the off position 1 Rotate both vise jaws to the station suitable for the key being duplicated Insert the blank key and pattern key into the vise jaws using the appropriate method described under Aligning Keys in the Vise Jaws Be sure that both keys are laying level in the vise jaws and are not tilt ed Lower the key gauge to align the keys using an appro priate method as described under Aligning Keys found in the previ
10. n the vise jaws Keys with shoulders WARNING Do not install or remove keys unless the off on switch is in the off position Both the pattern key and the key blank must be properly aligned and securely clamped in the vise jaws To do this slide the machine s carriage assembly towards the right and position the appropriate key blank in the carriage s RIGHT vise jaw with the head of the blank pointing to the left Ensure that the shoulder of the key blank is located approximately to the left of the vise jaw s left edge Holding the key blank firmly and level against the jaw tighten the wing nut Position the pattern key in the car riage s LEFT vise jaw in a similar manner only this time allowing a 4 gap between the shoulder of the key and the edge of the vise jaw Next lower the key gauge and position the carriage so that the left edge of the gauge s RIGHT prong contacts the edge of the key blank s shoulder see Figure 3 Loosen the wing nut securing the pattern key and repo sition the key so that its shoulder is in contact with the Figure 3 Aligning shoulders of keys with key gauge left edge of the LEFT prong of the key gauge Check to ensure that the pattern key and blank key s shoulders are snug against the key gauge and both keys are positioned level not tilted in the vise jaws Retighten the wing nut Aligning keys in the vise jaws Keys without shoulders On keys such as the Ford doubl
11. nut and bolt and is adjustable To check the adjustment raise carriage without keys in vise jaws and rotate the cutter by hand The cutter should not contact the vise jaw When the carriage stop is properly adjusted there should be a space of 008 between the vise jaw and the cutter this is about the thickness of an ordinary busi ness card Do not allow a greater distance since this many affect the depth of cut Cleaning Your machine should be kept clean of all filings and dust The most critical areas are the carriage jaws and shafts A one inch paint brush is ideal to brush these areas of the machine The shafts should be wiped peri odically with a lightly oiled cloth We suggest brushing the jaws often as even a single filing can alter the accu racy of the machine 15 16 ay g MLOU A Member of the Kaba Group Kaba lico Corp P O Box 2627 27802 400 Jeffreys Rd Rocky Mount NC 27804 Tel 252 446 3321 Fax 252 446 4702 www kaba ilco com Printed in USA 125191
12. on once annually Refer to the label on the motor for lubri cation details and recommended interval o HOW TO DUPLICATE KEYS General key duplication procedures WARNING Do not install or remove keys unless the off on switch is in the OFF position Always wear eye protection when operating this machine There are four procedures that the machine operator per forms to insure proper duplication of a key 1 Selection of the proper key blank Compare the head length and key blank s cross section width angle and location of grooves with the key to be duplicat ed to assure that a proper match has been made Ensuring both four way vise jaws have been placed in the proper position for the type of key to be duplicat ed See Using the four way vise jaws section of this manual Proper alignment of the pattern key and blank key within the vise jaws See Aligning keys in the vise jaws Actual duplication of the pattern key which can be properly accomplished only after the previous steps are performed N w R Using the four way vise jaws Your 045 HD is equipped with the KABA ILCO versatile Four way Super Jaw 3 vise jaws They feature four unique clamping surfaces to securely grip virtually any typical cylinder key see Fig 1 Figure 1 Rotate both jaws as a set 10 Using the four way vise jaws cont To obtain the best gripping action possible it is neces sary to ass
13. otor pulley 2 3L 181 024B 181 Key Gauge Spacer Left 48 025 48 V Belt 3L 180 182 024B 182 Key Gauge Spacer Right 49 045 49 Cutter guide stylus 183 040 183 1 4 20 Lockwasher 50 040 50 Carriage stop 184 040 184 1 4 20 Hex Nut 52 040 52 Socket hd screw 8 32 x 1 1 2 186 045 186 6 32 x 3 8 set screw 53 045 53A Cutter guide binding washer 187 045 187 dowel 54 045 54 Cutter guide binding screw 188 045 188 dowel spring 55A 045 55A Adjusting screw 189 045 189 Adjustment dial 56 040 56 Key gauge 190 045 190 Cutter guide label 57 024B 57 Key gauge bracket 194 045 194 10 flat washer 58 024B 58 Key gauge dowel pin 195 045 195 10 32 x 1 2 Button hd screw 59 025 59 Key gauge housing 198 1045 198 7 16 14 x 3 4 set screw 60 025 60 Cap screw 8 32 x A 199 1045 199 1 2 20 x 1 2 set screw 61 025 61 Circuit Breaker ETA 1658 IM 045HD IM Instruction manual 62A 025 62A On Off switch NS 025 240 220V HP motor 65 045HD 65 Machined base 68 040 68 Electrical cover 70 040 70 Rubber mount 74 040 74 Truss head screw 8 32 75 040 75 Motor hp 115V co HOW TO DUPLICATE KEYS Unpacking The 045 HD key machine is shipped completely assem bled except for the carriage handle Upon unpacking the machine locate the carriage handle and thread it into the carriage Test keys A series of cut keys are supplied with your machine These keys were cut on your machine and represent the result of our qu
14. ous section see page 10 After the keys are aligned return the gauge to its up position N w R Press the off on switch to the on position 6 Lift the carriage with both hands see Figure 5 7 Move the carriage to line up the cutter guide with the shoulder of the pat tern key then shift slightly away from the shoulder Do not permit the cut ter to touch the shoulder of the key blank 8 Press in on the carriage while guiding it to the left Carefully trace the cuts of the pattern key with the cutter guide The cutter will make a corresponding cut in the key blank When the cut closest to the tip of the pattern key has been traced retrace the cuts by guid ing the carriage to the right This will clear away any metal not removed during the initial pass over the key blank 9 Press the off on switch to the off position Remove the blank key Press the switch to the on position and remove any burrs that remain by contacting the key lightly against the deburring brush Return the switch to the off position 10 Operating Tips When duplicating a key avoid an irregular jerking motion in the movement of the carriage Acquire a smooth steady motion using both hands on the carriage to guide it Apply the same degree of pressure each time a key is duplicated Excessive pressure may cause over cutting It is sometimes best to practice on a few keys until the operator learns
15. plug Repair or replace damaged or worn cords immediately w INTRODUCTION UNPACKING Congratulations You ve purchased a superior key cutting machine The Model 045 HD manual Performance Series key machine you ve just purchased incorporates the latest improvements in design for key duplicating machines of its type This machine features exclusive four way vise jaws designed to accommodate virtually any standard cylinder key without the need for adapters Even double sided automotive keys can be duplicated with ease the four way jaws include stations ideally suit ed to gripping these keys and is capable of gripping them in the groove or milling for enhanced clamping perfor mance when necessary Accurate easy to operate and maintain the model 045 HD delivers excellent performance at an economical Unpacking instructions Your 045 HD key machine has been shipped to you in a sturdy specially cushioned container to prevent the pos sibility of damage during handling and shipment Once the machine is removed from the carton it should be set up on a level workbench and wiped free of all rustproof ing oil The machine is adjusted at the factory and test keys have been cut on it but it is recommended that you check the adjustments to make sure they have not slipped or shifted during transit see page 13 Adjusting for depth of cut Safety The 045 HD has been engineered to duplicate cylinder paracentric keys
16. sible accuracy This is very important as many locks are designed with close fit tol erances and the keys you duplicate are often themselves copies functional but just barely so The more accurate your key machine is adjusted the closer your duplicates will match their originals resulting in fewer non func tional miscuts It is very important to understand that adjusting your machine is not a one time procedure As the cutter on your machine wears down the machine must be adjust ed to compensate It is good shop practice to check you machines depth adjustment every 2 4 weeks based upon your store s key cutting volume and readjust as necessary You will find that re calibration is seldom needed but by checking and correcting BEFORE cus tomers begin returning miscut keys you will create a rep utation for your store as a good place to have keys duplicated 13 ADJUSTMENTS Adjusting for spacing There is no adjustment for spacing However if a key gauge assembly is ever replaced the key gauge must be fitted to the machine after it has been installed To do this first install a pattern key and key blank and align these against the cutter guide and cutter Then lower the key gauge and file the appropriate finger of the gauge to allow contact with the shoulder of both keys Adjust the Carriage Stop The purpose of the carriage stop is to prevent the cutter from hitting into the right vise jaw The stop is a
17. t touch the key blank after one rotation proceed to change the ad justment To adjust the cutter guide loosen the binding screw on top of the cutter guide slightly see Fig 7 amp 8 Once you have loosened this screw the depth Depth Dial Figure 8 Binding Plate i adjustment dial can be Binding rotated to the left to Screw decrease depth of cut or i to the right to increase Carriage depth of cut Again Stop proper adjustment will be achieved when the cutter just barely grazes the key blank before it while the cut ter guide is in contact with the other key blank Retighten the binding screw once the calibration process is com pleted Recheck after tightening to assure that adjust ment did not shift Each calibration mark on the depth adjustment dial is equivalent to approx 0015 1 1 2 thousandths of an inch As you can see this system can allow for very pre cise adjustment of your new key machine In fact if you have a key micrometer or dial caliper available you can adjust your machine with factory accuracy To do this you would simply duplicate a key and measure cuts on both the pattern key and the duplicate key for com parison This would show any deviation that existed and whether the duplicate cuts were too deep or too shallow and by how much With this information you can use the depth adjustment dial on your machine to calibrate your machine for best pos
18. to impart a steady uniform pressure to the carriage UI Figure 5 12 Replacing the Cutter The P 23XMC cutter used on this machine is 2 in diameter 093 thick and has a hole It s a milling cut ter made out of high speed steel It has a flat left side which is excellent for making deep cuts when these cuts are next to the shoulder such as on GM Chicago etc No warranty is placed on the cutter operators should treat it with care and avoid harsh usage Do not force the carriage up causing the key blank to bang into the cut ter and do not apply heavy pressure when cutting Also do not let the cutter run into the vise jaw this will dull the cutter quickly As with any metal cutting instrument the P 23XMC will dull with usage There are three ways to tell when a cut ter is dull and requires replacing 1 Time a dull cutter takes longer to make the cuts 2 Sound a dull cutter will emit a shrill sound as it runs across the key blank 3 Burrs a dull cutter will not cut away the metal but will roll it away When this occurs there will be a buildup of metal burrs on the underside of the key If this buildup is heavy the cutter is dull A sharp cutter leaves little or no burrs To replace the cutter use two wrenches one wrench for the cutter nut and one wrench for the cutter shaft Set the two wrenches in position and loosen the cutter nut Note that the cutter nut has a reverse
19. uch machine product of component thereof is warranted irrespective of whether or not payment is eventually made These warranties are in lieu of and not in addition to any other warranty of condition expressed or implied including without limitation merchantability fitness for a particular purpose or latent defects The buyer releases KABA ILCO from any liability for any reason other than a breach of its warranties hereunder The liability of KABA ILCO shall in no case includ ing negligence exceed the purchase price of the defective machine nor shall KABA ILCO be liable for any personal injuries property damage or conse quential damages Use only genuine KABA ILCO replacement parts on this machine Serial number WARNING SAFETY NOTICE IMPORTANT Please read carefully before operating machine Safety begins with education and continues with proper application All personnel who operate your machine should read the supplied Operator s Manual for informa tion on how to properly operate it The likelihood of acci dents and miscuts will be greatly reduced General safety Safety glasses must be worn to reduce the possibility of eye injury while operating or in the immediate vicinity of key cutting equipment Always turn machine off before making adjustments or inserting or removing keys Machine should be located in an area accessible only by authorized operators Location must be such that customers an
20. uched while it is in operation The operator should take care to ensure that loose fitting clothing long hair etc are kept from the area of machine operation Your machine has been specially designed and built for key cutting purposes only and should be operated according to the Operator s Manual All other uses are strongly discouraged as potentially dangerous and should not be attempted Such use will immediately void the machine s warranty Some states have specific age restriction concerning the operation of certain types of equipment Check local and state ordinances for compliance Electrical problems should be referred to qualified repair technicians If the machine is under warranty contact KABA ILCO at the address printed on the cover KABA ILCO also offers repair service for out of warranty machines Contact KABA ILCO for details Always unplug the machine before removing the hood or changing the cutter wheel surface with or without yellow stripes is the equip ment grounding conductor If repair or replacement of the electric cord or plug is necessary do not connect the equipment grounding conductor to a live terminal Check with a qualified electrician or service personnel if the grounding instructions are not completely understood or if in doubt as to whether the machine is properly grounded Use only 3 wire extension cords that have 3 prong grounding plugs and 3 pole receptacles that accept the machine s
21. ure that the proper vise jaw position is select ed for each key you duplicate The vise positions are explained below and proper usage shown in figure 2 Standard for holding regular cylinder keys such as house keys single sided automotive keys padlock keys with one or two shoulders Narrow for holding the 1092B and other narrow width keys Wide for holding the Ford double sided keys and simi lar types either primary or secondary When positioning the keys in the vise jaws lay the key so that its center ledge is flat against the top surface of the jaw X Ideal for holding most double sided convenience keys used on most current automobiles Grip these keys by the grooves rather than the blade edge where the cuts are located see Fig 2 Figure 2 Super Jaw 2 vise jaw shown gripping a typical automotive key Using standard position Arm Using X position me Using wide position Using narrow position To reposition the vise jaws as from Standard to Wide first loosen the wing nuts Then lift upward on the top and bottom of each vise jaw as a complete unit to raise them above their seat in the carriage Rotate the jaws until the chosen vise position is facing toward the rear of the machine and lower the jaws back into contact with the carriage Both left and right vise jaws should be rotat ed to the same position HOW TO DUPLICATE KEYS Aligning keys i
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