2749A-045 Manual

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.

This manual applies specifically to the 045 HD

Performance Series key machine. It properly identifies your

odel 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 service manual should accompany the machine.

When seeking service information about this machine,

refer to Model No. 045 HD and the part number desired

(

see pages 6 to 8). Note that many parts are not inter-

changeable with other ILCO machines.

CONTENTS

Warranty ..............................................................................2

Safety information ................................................................3

Introduction / unpacking ......................................................4

Operating parts (illustrated)..................................................5

Operating parts identification (names and part numbers) ..5

Exploded view ......................................................................6

Exploded view parts list / unpacking / test keys ..................8

How to duplicate keys ..........................................................9

The cutting operation / replacing the cutter ......................12

Adjustments ........................................................................13

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 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 r

eason, 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 gr

eater

certainty, any machine not operated in accordance

with KABA ILCO printed instructions or operated

beyond its rated capacity shall not be cover

ed by this

or any other war

ranty

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 such 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 : _______________________________

ONE YEAR LIMITED WARRANTY

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-gr

ounded outlets!

•

o 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 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 befor

e removing the hood

or changing the cutter wheel.

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 and 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.

• At no time should the mechanically-driven parts of

the machine be touched 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.

Grounding instructions

• In the event of a malfunction or breakdown, ground-

ing provides a path of least resistance for electric cur-

ent to r

educe the risk of electric shock. This machine

is equipped with an electric cor

d 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 accor

dance with

all local codes and ordinances.

• Do not modify the plug provided - if it will not fit the

outlet, have the pr

oper 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 gr

een outer

surface (with or without yellow stripes) is the equip-

ment-grounding conductor. If repair or replacement of

the electric cor

d or plug is necessar

, do not connect

the equipment gr

ounding conductor to a live ter

minal.

• Check with a qualified electrician or service personnel

if the gr

ounding 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

ounding plugs and 3-pole r

eceptacles that accept

the machine’

s plug.

• Repair or replace damaged or worn cords immediately.

Congratulations!

You’ve purchased a superior key cutting machine.

INTRODUCTION / UNPACKING

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”).

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

The 045 HD has been engineered to duplicate cylinder

(paracentric) keys. 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

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.

Safety

CAUTION! DO NOT DESTROY OR DISCARD THIS SPECIAL SHIPPING CAR

TON.

STORE IT CAREFULLY IN A SAFE PLACE. THIS CARTON SHOULD BE USED

WHENEVER THE MACHINE IS MOVED OR SHIPPED.

Part no. Identification

024B-1 Carriage

025-3X Vise jaw assembly

025-8 Wing nut

045-23

Car

riage 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

OPERATING PARTS

Key gauge

Safety shield

Nylon

brush

On / Off

power switch

Carriage

Vise jaw

assembly

Operating parts identification

Wing nut

afety hood assembly

Carriage

shaft

Cutter guide

Depth

ial

EXPLODED VIEW

Ref. Part no. Description

1 045HD-1 Carriage

1X 045HD-1X Carriage assembly

2 025-2 Carriage stud

3X 045HD-3X Vise jaw assembly (Super Jaw 3)

4 025-4 Vise jaw spring

6X 025-6X Thrust bearing set

8 025-8 Wing nut

9X 040-9X Carriage handle

20 040HD-20 Cutter shaft bearings

21 025-21 Carriage shaft bushing

23 045HD-23 Carriage shaft

32 024B-32 Button head. screw, 10-24 x

⁄8"

36 025-36 Cutter nut, N-4

37 025-37 Cutter spacer; left

38 P-X23MC P-X23MC cutter

40 040HD-40 Cutter shaft

41 025-41 Cutter shaft pulley

43 814-00-51 Nylon brush

45 024-45 Brush bolt washer,

⁄1

46A 025-46A Hex head screw,

⁄16-18 x

⁄4

47 025-47 Motor pulley 2" - 3L

48 025-48 V-Belt, 3L-180

49 045-49 Cutter guide (stylus)

50 040-50 Carriage stop

52 040-52 Socket hd. screw 8-32 x 1-1/2"

53 045-53A Cutter guide binding washer

54 045-54 Cutter guide binding screw

55A 045-55A Adjusting screw

56 040-56 Key gauge

57 024B-57 Key gauge bracket

024B-58

Key gauge dowel pin

025-59

Key gauge housing

60 025-60 Cap screw, 8-32 x

⁄2"

025-61

Cir

cuit Br

eaker

, ETA 1658

62A

025-62A

On/Off switch

65 045HD-65 Machined base

040-68

Electrical cover

70 040-70 Rubber mount

74 040-74 Truss head screw, 8-32

75 040-75

Motor

⁄4hp,115V

Ref. Part no. Description

79 024B-79 Key gauge spring

84 024B-84 Clip

86X 045HD-86X Safety hood assembly

87 045HD-87 Safety shield

89 045-89 #10 Lockwasher

90 025-90 Nut, #10-32

91 024B-91 Power cord

92 024B-92 3 wire motor cable

100 040HD-100 Cutter spacer; right

101 025-101 Motor pulley set screw

106 040-106 Chip tray

109 025-109 Bearing washer

110 025-110 Wave washer

129 040-129 Locking nut (8-32)

146 040-146 Power cord strain relief

150 040-150 Switch screw (6-32 x 1/4")

151 040-151 Set screw (8-32 x 3/8")

160 025-160 Caution label

163 045-163 Hood Screw

171 025-171 Cutter pulley set screw,

⁄8" -18

181 024B-181 Key Gauge Spacer - Left

182 024B-182 Key Gauge Spacer - Right

183 040-183 1/4-20 Lockwasher

184 040-184 1/4-20 Hex Nut

186 045-186 6-32 x 3/8" set screw

187 045-187 dowel

188 045-188 dowel spring

189 045-189 Adjustment dial

190 045-190 Cutter guide label

194 045-194 #10 flat washer

195 045-195 10-32 x 1/2" Button hd. screw

198

045-198

7/16-14 x 3/4" set scr

199 045-199 1/2-20 x 1/2" set screw

IM 045HD-IM Instruction manual

NS 025-240 220V

⁄4 HP motor

EXPLODED VIEW PARTS LIST

Refer to pages 6-7 for illustration

HOW TO DUPLICATE KEYS

Proper key cutting techniques

Even though your 045 HD key machine is designed to

make key cutting fast, efficient and accurate, operator

kill is important. The actual mechanics of placing keys

ithin 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 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.

Keep the cutter clean. Don't let any foreign objects or

instr

uments blunt it. This cutter is a precise cutting

tool and should be handled with care.

7. Lubrication requirements for your new “HD”

Per

for

mance Series key machine ar

e minimized thr

ough

the use of sealed, per

manently lubricated cutter spindle

bearings. The carriage shaft however, should be inspect-

ed on a r

outine basis, and wiped with a dr

, clean cloth

to r

emove 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 lubrication

once annually. Refer to the label on the motor for lubri-

cation details and recommended interval.

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 quality 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.

Unpacking

he 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.

HOW TO DUPLICATE KEYS

Using the four-way vise jaws (cont.)

o obtain the best gripping action possible, it is neces-

sary to assure 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).

o r

eposition the vise jaws, as fr

om 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 car

riage. Rotate the jaws

until the chosen vise position is facing towar

d the r

ear of

the machine and lower the jaws back into contact with

the car

riage. Both left and right vise jaws should be r

otat

ed to the same position.

Figure 2

Figure 1

General key duplication procedures

ARNING: 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.

2. 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.

3. Proper alignment of the pattern key and blank key

within the vise jaws. See “Aligning keys in the vise

jaws”.

4. Actual duplication of the pattern key; which can be

properly accomplished only after the previous steps

are performed.

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).

Rotate both

jaws as a set

Using standard position

Using X position

Using wide position Using nar

ow position

Super Jaw 2

vise jaw shown

gripping a typical

automotive key

HOW TO DUPLICATE KEYS

Aligning keys in the vise jaws

Keys without shoulders

n keys such as the Ford double-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.

“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.

Aligning keys in the vise jaws

Keys with shoulders

ARNING: 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

⁄8” 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

left edge of the LEFT prong of the key gauge.

Check to ensure that the pattern key and blank

key‘s shoulders ar

e snug against the key gauge and

both keys ar

e positioned level (not tilted) in the

vise jaws. Retighten the wing nut.

Figure 3

Aligning shoulders of keys with key gauge

Figure 4

Use of gauge with various key types

Shoulder

Tip

Recessed tip

THE CUTTING OPERATION / REPLACING THE CUTTER

General Operating Sequence

WARNING: Do not install or remove keys unless

the off/on switch is in the of

f position.

. Rotate both vise jaws to the station suitable for the

key being duplicated.

2. 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.

3. Lower the key gauge to align the keys using an appro-

priate method as described under “Aligning Keys …”

found in the previous section (see page 10).

4. After the keys are aligned, return the gauge to its “up”

position.

5. 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 r

emove 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 to impart a steady, uniform pressure

to the carriage.

Figure 5

Replacing the Cutter

The P-23XMC cutter used on this machine is 2

⁄4” in

diameter, .093” thick and has a

⁄2” 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

⁄4" wrench

for the cutter nut and one

⁄2" wrench for the cutter shaft.

Set the two wrenches in position and loosen the cutter

nut. Note that the cutter nut has a reverse thread and

turns downward to loosen. Remove the spacer washers

and the dull cutter. Install the new cutter, the washers,

and the nut.

ADJUSTMENTS

Adjusting for depth of cut

o 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).

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 6

Depth Adjustment

Dial

Binding

screw

Adjustment is

correct when

both key blanks

touch

Figure 7

Carriage stop

adjusting screw

be a high point on the cutter; the adjustment should be

made to the high point. If the cutter does not 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 & 8).

Once you have loosened

this screw, the depth

adjustment dial can be

rotated to the left (to

decrease depth of cut) or

to the right (to increase

depth of cut). Again,

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 possible 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, r

esulting 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 r

eadjust as

necessary. You will find that re-calibration is seldom

needed, but by checking and cor

ecting BEFORE cus

tomers begin r

etur

ning miscut keys, you will cr

eate a r

ep-

utation for your stor

e as a “good place” to have keys

duplicated.

Figure 8

Depth

Dial

Binding

Screw

Carriage

Stop

Binding

Plate

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 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.

Printed in USA

125191

Kaba Ilco Corp.

P O Box 2627 (27802)

400 Jeffreys Rd., Rocky Mount, NC 27804

Tel.: (252) 446-3321 • Fax: (252) 446-4702