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Operating manual - English

DUO

Copyright Silca 2 010

11

5

ACCESSORIES PROVIDED

it is advisable to always have certain spare parts on hand. It is advisable to always have a tool box con-

taining: tools, cutting tools, brushes, belts and small replacement parts.

DUO is supplied with a full range of accessories. The accessories provided by Silca are all that is nec-

essary to carry out the operations for which the machine is designed.

STEEL PIN Ø 1,20
2 pcs

STEEL PIN Ø 1,70
2 pcs

FUSES 5X20 (2 pcs)

4 Amps rapid (230V)
8 Amps rapid (120V)

2,5 mm ALLEN KEY

3 mm ALLEN KEY

19 mm SPANNER

CUTTING TOOL
UNCLAMPING PIN

ADJUSTING BAR
2 pcs

4 mm ALLEN KEY

5 mm ALLEN KEY

STEEL BAR
2 pcs

CLEANING BRUSH

ADJUSTING PINS
2 pcs

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Summary of Contents for DUO BRAZIL

Page 1: ...Operating manual D434685XA vers 2 0 EN ...

Page 2: ...ed in India by MINDA SILCA Engineering Ltd Plot no 37 Toy City GREATER NOIDA U P 201308 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 o...

Page 3: ...de 20 8 1 2 Clamp rotation 20 8 1 3 Carriage translation on DUO key cutting machine 21 8 1 4 Carriage translation on DUO BRAZIL key cutting machine 21 8 1 5 Flared cuts cutting bit keys right hand carriage 22 8 2 Cutting flat cylinder and vehicle keys LEFT HAND carriage 23 8 2 1 Using the accessories 25 8 3 Cutting double bit pump and mail box keys RIGHT H carriage 27 8 3 1 Cutting bit and double ...

Page 4: ......

Page 5: ...iption of machine and safety devices Ch 2 3 4 5 Proper use of machine Ch 6 7 8 Maintenance Ch 9 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 Fig 2 1 Head 2 Rim 3 Stop 4 Blade 5 Tip 6 Back 7 Cuts 8 Stem 9 Bit 1 1 1 3 3 3 7 7 8 2 2 5 5 5 4 6 WITH LE...

Page 6: ...ines all responsibility in such cases It is therefore indispensable to read the operating manual carefully in order to make the best use of the DUO and benefit from its potential Instructions manual The instructions manual provided with the machine is essential to its proper use and to carry out th e necessary maintenance We therefore recommend protecting the manual from damage in a safe sheltered...

Page 7: ...ovements 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 manufac turers for repairs or servicing 4 check the contents of the box which should comprise 1 DUO key cutting machin...

Page 8: ...ys G left tracer point for flat keys G1 centesimal ring left tracer point H right hand carriage movement lever J clamps for bit keys K clamps knobs right hand carriage L tilting movement activating pin right hand car riage M milling cutter for bit keys N right tracer point for bit keys N1 centesimal ring right tracer point O handwheel for carriage movement P brush Q top cover R lamps S chippings t...

Page 9: ...or flat keys G1 centesimal ring left tracer point H right hand carriage movement lever J clamps for bit keys K clamps knobs right hand carriage L tilting movement activating pin right hand car riage M milling cutter for bit keys N right tracer point for bit keys N1 centesimal ring right tracer point P brush Q top cover R lamps S chippings tray T main switch U motor on switch V supply socket V1 fus...

Page 10: ... They move horizontally and frontally controlled by handles C and H The DUO machine carriages can be locked into a fixed position and in this way achieve translation by means of the flywheel located on the right hand side of the machine chap 8 1 3 page 21 Attention not available on Duo Brazil version The carriages are so designed as to avoid accumulation of dust or cutting swarf The machine is des...

Page 11: ...amps have two gauge tabs left hand carriage with which to adjust key alignment Brush The brush P is used to eliminate burrs from the cuts and is made of non abrasive material 4 1 Technical Data ELECTRICAL PROPERTIES 230V 50Hz 300W 1 2A 120V 60Hz 250W 2 3A CUTTING TOOLS HSS Super Rapid Steel MOTOR One speed single phase 230V 50Hz 1400 rpm 120V 60Hz 1700 rpm MOVEMENTS by gear on rectified carriage C...

Page 12: ... circuit The main parts of the electric circuit on the DUO are listed below 1 Main socket with fuses 2 Safety main switch 3 Illuminated switch 4 Motor 230V 50Hz 120V 60Hz 5 Condenser 6 Lamps 2 3 4 1 blue blue brown brown blue brown brown blue yellow green 1 2 3 4 5 6 ...

Page 13: ...rts DUO is supplied with a full range of accessories The accessories provided by Silca are all that is nec essary to carry out the operations for which the machine is designed STEEL PIN Ø 1 20 2 pcs STEEL PIN Ø 1 70 2 pcs FUSES 5X20 2 pcs 4 Amps rapid 230V 8 Amps rapid 120V 2 5 mm ALLEN KEY 3 mm ALLEN KEY 19 mm SPANNER CUTTING TOOL UNCLAMPING PIN ADJUSTING BAR 2 pcs 4 mm ALLEN KEY 5 mm ALLEN KEY S...

Page 14: ...nditions To ensure that the best use is made of the DUO key cutting machine certain parameters must be bo rne in mind damp badly ventilated sites should be avoided The ideal conditions for the machine are temperature from 10 to 40 C relative humidity approx 60 6 3 Positioning Place the key cutting machine on a horizontal surface solid enough to take the weight 23 Kg To facilitate operation and mai...

Page 15: ... 21 not available on Duo Brazil version Right hand carriage Carriage lever H Carriage release pin B1 not available on Duo Brazil version Carriage advancement flywheel O with carriage locked chap 8 1 3 page 21 not available on Duo Brazil version Tilting movement activating pin L Fig 9 not available on Duo Brazil version 6 5 Separate parts The separately packed parts must be installed on the DUO key...

Page 16: ...2 010 6 7 Cutter shield The shield W is mobile and can be placed over the cutter when not in use to operate the left hand carriage take shield W to the right fig 11 to operate the right hand carriage take shield W to the left fig 12 Fig 11 Fig 12 W W ...

Page 17: ...ig 13 A Proceed as follows 1 Ensure that the key cutting machine is off by unplugging the power cable 2 Place the adjusting keys provided on the clamps fig 13 B 3 Check that the adjusting keys adhere properly to the clamps 4 Turn the gauge rod D2 towards the operator so that the gauges come into contact with the adjusting keys fig 14 Lower the gauge rod Fig 14 5 Release the carriage by raising the...

Page 18: ...perations until regulation is complete then tighten the tracer point locking grub screw G2 Fig 15 Fig 16 Turn the nut to the RIGHT clockwise to take the tracer point down Result LESS DEEP CUTS Fig 17 Turn the nut to the LEFT anticlockwise to take the tracer point up Result DEEPER CUTS 0 025 mm 0 1 mm A G1 B G2 cutting tool G1 G2 cutting tool G1 G2 ...

Page 19: ...e 2 clamps with their knobs K 5 Release the carriage by turning the pin B1 not available on Duo Brazil version 6 Use the lever H to raise the carriage and take the right hand side of the clamp up against the left hand side of the tracer point and cutter fig 19 7 The ideal condition is for both tools tracer point and cutter to be in contact with the relative side of the clamp If this is not so loos...

Page 20: ...ontal position by means of the pin L 4 Raise the carriage and take the adjusting keys or pins into contact with the tracer point and cutting tool fig 20 5 Turn the cutting tool manually in the opposite sense to the rotation and check that it skims the adjust ing key or pin in several places 6 If necessary regulate the cutting depth by means of the tracer point as described loosen grub screw N3 and...

Page 21: ...ht Silca 2 010 19 Fig 21 Turn the nut to the RIGHT clockwise to take the tracer point down Result LESS DEEP CUTS Fig 22 Turn the nut to the LEFT anticlockwise to take the tracer point up Result DEEPER CUTS cutting tool N1 cutting tool N1 ...

Page 22: ...n with the carriage in a mobile free position carriage released ATTENTION if cutting is carried out with the carriage in a fixed position before proceeding release the carriage not to be used Attention not available on Duo Brazil version ATTENTION if cutting is carried out with the carriage in a free position use handle C or H to raise and move the carriage 8 1 1 Carriage release right or left han...

Page 23: ...nt and cutter by means of the handle C or H turn the flywheel O to move the carriage sideways and carry out cutting If the carriage to be used for cutting is in a mobile free position carriage released to move it use the handle C or H to both raise and move the carriage Fig 25 8 1 4 Carriage translation on DUO BRAZIL key cutting machine use the handle C or H to both raise and move the carriage Fig...

Page 24: ...e Tilting clamps The clamps on the right hand carriage used to cut bit double bit and rim keys may be of th e tilting type so that the cuts can be flared To activate tilting pull out the pin L To deactivate tilting inser t the pin L to lock the clamps in the fixed horizontal position Fig 27 Fig 28 Fig 29 L L ...

Page 25: ...mps and turn to the required position fig 24 Side A of the clamp for keys to be fitted on their backs keys with double cuts without groove and cruciform keys fig 30 Side B of the clamp for keys placed on their backs and having cuts with a depth of less than 3 9 mm fig 30 Side C and D of the clamp for keys to be cut on both sides and locked on the groove fig 30 D A B C D A B C DUO BRAZIL key cuttin...

Page 26: ... ATTENTION make sure the gauge rod has been lowered When the DUO key cutting machine has been turned on by means of switch U it is ready for cutting 3 Take the carriage towards the tracer point cutter fig 32 4 Move the carriage from right to left to cut the key see chap 8 1 3 page 21 In case of double cuts repeat the operation in the second side of the key 5 Turn off the machine with witch U befor...

Page 27: ...pose is to ensure that the key protrudes sufficiently to be cut properly fig 33 B fig 33 C For keys with narrow thin stems two pins must be used fig 33 B thesecond one to give asecure grip on the key If the key thickness is too fine to guarantee a good grip in the clamps a pin must be used fig 33 A ATTENTION the pins provided have two different diameters 1 20 mm and 1 70 mm It is essential to use ...

Page 28: ...o the slot in the clamps 3 Butt the key stop against the bars 4 Secure the keys in the clamps 5 Remove the bars from the clamp grooves to prevent it being touched by the tracer point or cutting tool 6 Cut the first side 7 Repeat the operation turning the keys in the same direction for the other positions Fig 34 Tip stop with a bar The bars can be used with keys which have no stop fig 35 proceed as...

Page 29: ... and DUO BRAZIL versions Ø min 3 5 max 7 mm max 125 mm max max 12 mm 15 mm min Ø min 3 5 max 7 mm 26 mm max 30 mm max 25 mm min 26 mm depth 12 mm max PUMP KEYS some models only The duplication is possible for keys with these characteristics DUO and DUO BRAZIL DUO POWER The duplication is possible for keys with these characteristics PUMP KEYS BIT and DOUBLE BIT KEYS PUMP KEYS MAIL BOX KEYS ONLY on ...

Page 30: ...L Clamp side for bit double bit keys and bit keys with central stop position 1 Clamp side for pump keys with ROUND stem position 1 turned 90 Clamp side for mail box keys position 2 Fig 39 DUO POWER Clamp side for bit double bit keys and bit keys with central stop position 1 Clamp side for pump keys position 2 turned 90 180 90 1 2 bit and double bit keys mail box keys DUO and DUO BRAZIL 1 2 1 pump ...

Page 31: ...n the right hand clamp placing the bit against the tracer point this will ensure that the two keys are perfectly aligned Note choose a translation system with fixed or free carriage chap 8 1 3 page 21 Attention not available on Duo Brazil version 6 Proceed with cutting fig 41 if necessary activate tilting to flare the cuts chap 8 1 5 page 22 7 Raise the carriage with the handle H and take the orig...

Page 32: ... the handle H go on to the next cutting position and continue from point 6 8 When cutting is finished turn off the switch U and remove the keys Fig 42 8 3 3 Cutting mail box keys ATTENTION only on DUO and DUO BRAZIL versions Note check that the clamps are locked into the fixed position 1 Prepare the clamps with the required side facing the cutter and tracer point 2 Loosen the clamp handles slightl...

Page 33: ...mp Note choose a translation system with fixed or free carriage chap 8 1 3 page 21 Attention not available on Duo Brazil version 5 Start the machine and proceed with cutting 6 Raise the carriage with the handle H and take the cut key into contact with the tracer point to com plete cutting 7 Take the carriage back with the handle H go on tothe next cutting position and continue from point 6 8 When ...

Page 34: ...opyright Silca 2 010 Fig 45 The duplication is possible for keys with the following characteristics DUO POWER max 20 mm max 7 mm max 15 mm mn Ø min 3 5 max 7 mm 14 mm 2 1 2 90 pump keys ROUND stem 1 2 pump keys FLAT stem Mottura type 2 ...

Page 35: ...nts 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 9 1 Replacing the cutting tool In order to substitute the cutting tool you don t need to remove t...

Page 36: ...ket 2 Remove the swarf tray S fig 5 page 6 3 Before to turn the machine onto its back take the carriages externally to the end of run left hand car riage all to the left right hand carriage all to the right to avoid contacts between cutter tracer point and clamps during movement 4 Turn the machine onto its back firmly holding it on handles C and H fig 47 Fig 47 C H ...

Page 37: ...4 Remove the locking rod from the motor shaft Fig 48 9 4 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 cut ting tool brush Tension ATTENTION remove the mains plug 1 Loosen the 4 screws Q1 and remove the top cover Q fig 49 2 Access the bottom part chap 9 2 page 34 and loosen the 4 nuts S1 of the plate motor fig...

Page 38: ... then exert a lit tle pressur e into the m ain pulley turning it manually 4 Replace the fan and the top cover Fig 51 9 5 Replacing the tracer point Left hand tracer point ATTENZIONE remove the mains plug 1 Loosen the 4 screws Q1 and remove the top cover Q fig 49 page 35 2 Loosen the screw G4 fig 52 3 Loosen the grub screw G3 4 Loosen the tracer point by turning it anticlockwise until is fully rele...

Page 39: ...t from this proceed as fol lows ATTENTION remove the mains plug 1 Release the carriage raise against the cut ting tool and take to the end of its run fig 2 Remove the chippings tray S 3 Release the nut S3 fig with the spanner 4 Use the Allen wrench to screw or unscrew the grub screw in order to move the carriage away from or towards the tracer point and cutting tool 5 Tighten the nut Fig 54 9 7 Re...

Page 40: ...e 4 screws Q1 and remove the top cover Q fig 49 page 35 2 Detach the 4 connectors V2 paying special attention to their position 3 Remove the switch making pressure on the tabs with a screwdriver 4 Fit the new main switch 5 Reconnect the 4 connectors V2 6 Replace the top cover and secure with the 4 screws Q1 Fig 56 Fig 57 V2 ...

Page 41: ... cover Q fig 49 page 35 2 Detach the 4 connectors S2 fig 58 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 r econnect the 4 connectors S2 paying special attention to their position 5 Replace the top cover and secure with the 4 screws Q1 Fig 58 S2 ...

Page 42: ...ng plate and remove the belt chap 9 4 page 35 6 Loosen completely only the 2 lower screws S1 the motor fixing plate and pull downwards 7 Install the new motor and tighten the 4 screws S1 slightly 8 Place the machine in position on the work bench 9 Install the belt and tighten it and tighten the 4 screws S1 fig 60 of the plate motor 10 Connect the 4 connectors S2 fig 58 to the motor on switch and f...

Page 43: ...NTION remove the mains plug 1 Loosen the 4 screws Q1 and remove the top cover Q 2 Loosen the light bulb this may be facilitated by removing the shield R1 or R2 3 Screw the new light bulb into the lamp 4 Replace the top cover and secure with the 4 screws Q1 Fig 61 T T Q1 Q1 R1 R2 ...

Page 44: ...e 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 ...

Page 45: ...acturer 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 address es of specialised Service Centres 11 1 How to request service The guarantee attached to DUO key cutting machines ensures free repairs or replacements of faulty parts within 24 months of purchase All other service calls must be arrang...

Page 46: ...Directives European Union DIRECTIVE 2006 42 CE Machines and with the EN ISO 12100 1 2003 EN ISO 12100 2 2003 EN ISO 14121 1 2007 Standards European Union DIRECTIVE 2004 108 CE Electromagnetic Compatibility and with the EN 61000 6 3 EN 61000 6 1 Standards European Union DIRECTIVE 2006 95 CE Low Voltage 09 and with the EN 60204 1 2006 Standards Claudio Tomasella of the Silca S p A Research Developme...

Page 47: ...SILCA S p A Via Podgora 20 Z I 31029 VITTORIO VENETO TV Tel 0438 9136 Fax 0438 913800 E mail silca silca it www silca biz Members of the Kaba Group ...

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