OPERATING INSTRUCTIONS FOR MEDECO® KEY MACHINES FOR MEDECO ORIGINAL, BIAXIAL®, MEDECO3®, KEYMARK® CLASSIC & KEYMARK X4® PRODUCTS MEDECO® HIGH SECURITY LOCKS ASSUMES NO RESPONSIBILITY FOR INJURY OR PROPERTY DAMAGE AS A RESULT OF IMPROPER USE OF MEDECO® KEY MACHINES. READ AND UNDERSTAND ALL INSTRUCTIONS AND SAFETY PRECAUTIONS BEFORE INSTALLING OR OPERATING ANY MEDECO® KEY MACHINE. CONTENTS Introduction……………………………………………………………… 3 Potential Hazards………………………………………………………….. 4 Installation Procedure…………………………………………………… 5 Operating Instructions………………………………………………….. 6 Original Key Machine……………………………………………. 6 Biaxial Key Machine………………………………………………. 7 Universal Key Machine (Original Product)…………….. 8 Universal Key Machine (Biaxial Product)……………….. 9 KeyMark Classic & KeyMark x4 Key Machine……………… 10 Maintenance and Adjustment………………………………………. 11 Adjusting Lever Resistance………………………………. 11 Checking Accuracy of Cut…………………………………. 11 Adjusting Cutter………………………………………………. 14 Adjusting Depth of Cut…………………………………….. 14 Adjusting Shoulder Spacing……………………………… 14 Changing Cutter……………………………………………….. 15 Cleaning Vise Jaw……………………………………………… 16 Installing Quick Change Pin……………………………….. 16 Ordering Instructions……………………………………………………. 17 Key Machine Parts…………………………………………….. 18 2 INTRODUCTION The Medeco and KeyMark key machines are designed and built to precision standards at Medeco solely for cutting Medeco or KeyMark keys; they do this by means of a rotating cutter powered by an integral motor. The cutter is positioned for each cut by a precision ground dial to determine the depth, and on angled-cut machines, the angle of each cut is set by an angling lever. The key machine is a high quality, extra heavy duty piece of equipment and incorporates many safety and mechanical features to ensure easy, hazard free operation. Several models are available: the original key machine cuts Medeco original keys and Medeco3 keys on original keyways, and the Biaxial key machine (with prefix B on the serial number) cuts Medeco Biaxial and Medeco3 Biaxial keys. The KeyMark Classic key machine is available for cutting KeyMark Classic keys and the KeyMark x4 machine cuts KeyMark x4 keys. The universal key machine (with prefix U on the serial number) cuts original and Biaxial keys and all Medeco3 keys, but does not cut KeyMark or KeyMark x4 keys. Factory conversion of the original and the Biaxial machines to the universal version is available. An optional air-powered slide assembly for providing vertical motion of the cutter wheel is available for the key machine. This option may be purchased with new key machines or adapted to an existing machine through factory modification. 3 POTENTIAL HAZARDS Although every precaution has been taken to guard against hazards, they may still exist if the machine is used improperly or if the safety features are removed or disabled. Never operate the machine without understanding its complete and safe operation. It is the machine owner’s responsibility to provide proper safety devices and equipment to safeguard the operator from harm and to ensure at all times that the machine meets all current government safety codes and standards. Observance of the potential hazards and installation maintenance and use of the machine in compliance with the instructions contained in this booklet are essential for safe operation. The potential hazards are marked as follows: Caution: Do not operate without guards in place! The potential hazards on the key machine have been reduced as much as possible by the placement of guards. Usage of the machine without the guards in place exposes the operator to potential serious injury from the rotating cutter and belt. The key machine should never be used without the guards in place. Caution: Rotating cutter! Although the cutter is well guarded, it still remains a potential hazard as it is extremely sharp and has a high rate of rotation when the power is on. Under no circumstances should anyone reach under the guard, even when the cutter is stationary. The key machine should never be used without the guards in place. Caution: Cutter will rotate on resumption of power if switch is in the “On” position! If the power is interrupted for any reason while the power switch is in the “On” position (cutter rotating), the cutter will resume rotation when the power is restored, unless the power switch is moved to the “Off” position. This should be noted, especially if the power cord is disconnected and the guards removed to change the cutter; the power switch should always be moved to the “Off” position before power is reconnected. Caution: Rotating belt! The drive belt from the motor has several potential pinch points and a high rate of rotation. Under no circumstances should any object be inserted under the guard while the power switch is in the “On” position. The key machine should never be used without the guards in place. Caution: Turn motor off before loading and unloading keys. Ensure keys are clamped before cutting! Because of the potential for a key to touch the rotating cutter and be thrown from the machine at a high speed, the motor should be turned off before keys are loaded or unloaded. The potential for keys to be thrown by the rotating cutter also exists if the keys are not clamped tightly in the vice. Always check that the clamp is tight before cutting a key. Warning: Pull lever handle in a vertical direction! Do not apply side pressure to handle! The handle which lowers the cutter is designed to be used with vertical pressure only. Any sideways pressure should be avoided, as it puts unnecessary strain on the handle itself and the linkage. Caution: Do not lift the key machine by the handle! The handles on the key machine are not designed to support the weight of the machine and therefore should not be used for lifting purposes. Failure to observe this caution may result in damage to the machine or possible injury if the handles fracture. The machine should be lifted by the base and motor only. Caution: Always ensure that the electrical requirements of the key machine motor match the electrical system into which the machine is being plugged! Key machines with 115V 60Hz motors are intended for use in North America, and key machines with 220V 50Hz are intended for use in Europe. Always check that the wiring of the electrical system in which the machine will be used match the label on the motor. Plugging a key machine into an improper system may result in damage to the machine or injury to the user. 4 INSTALLATION PROCEDURE Remove the key machine from the packing crate by lifting from the base or the motor. The machine should not be lifted by using any of the handles or guards. It should be installed on a flat, stable surface capable of supporting the ~100lb weight of the machine. Holes for optional use of mounting bolts are drilled in the base. Install the appropriate power cord into the pigtail on the back of the motor, and plug into a grounded electrical source, ensuring that the power switch is in the “off” position before connecting power. Route the electrical cable directly from the back of the motor so that no interference with the cutter is possible. The electrical cord should be checked periodically for nicks and cuts in the insulation and exposure of bare wires; if the cord becomes worn in this way, it should be replaced to minimize the possibility of electrical shock. Never pull the machine by means of the power cord. For installation of a key machine with the optional air-powered slide assembly, the air supply hose should be connected to a 55 - 60 psi (3.8 – 4.0 bar) air supply. 5 OPERATING INSTRUCTIONS The following procedure for operation should be followed to assure safe and dependable service. Because of the possibility of flying chips of metal, the operator should wear safety glasses with side shields at all times. Original Key Machine 1. Move power switch “I” to the “off” position before inserting an original key blank or making any adjustments to the settings. 2. Select the proper key blank by referring to pages iii and iv in the code book. 3. With the vise clear of shavings, fully insert key blank “A”. 4. Tighten vise jaw “B” finger tight. 5. Turn power switch “I” to the “on” position. 6. Move lever “C” to align the indicator with position #1 marked on top of slide “D”. 7. For depth of cut, rotate dial “E” to align the proper number with the indicator.* Figure 1 8. For angle of cut, depress button “F” allowing the base to rotate. For L, turn clockwise to stop; for C, use the center position; for R, turn counterclockwise to stop. Make sure that the base is firmly positioned by its detent; as failure to do so may result in damage to the vise and cutter. 9. Pull lever handle “G” down to stop with a gradual, continuous motion. Hydraulic valve “H” adjusts to control force. (See procedure for adjustment.) 10. Repeat steps 6 through 9 for the remaining cuts, advancing the key by moving lever “C” to the next position. 11. Turn power switch “I” to the “off” position. When the cutter has stopped, loosen vise jaw “B”. Do not attempt to remove the key blank until the power is off and the cutter has completely stopped. 12. Remove the cut key and buff to remove burrs. Figure 2 * Note that on some machines the dial is only marked for the .030” (full step) whereas on others the dial is marked both for the .030” (full step) and the .015” (half step) increments. As show in fig. 2 some positions on dial “E” have two numbers. The first of these two letters “J” is the half step increment indicator. Dial positions having only one number are half step increment indicators only. When cutting keys using the Medeco code book only the full step increment indicators “K” should be used.