Ilco Orion ECODRILL 2000 C/E User manual

®
Operating manual
D425330XA
vers. 3.0
ECODRILL 2000 C/E

(c) 2003 SILCA - Vittorio Veneto
This manual has been drawn up by ILCO ORION.
All rights reserved. No part of this publication may be reproduced or used in any form or by any means (photocopying, microfilm
or other) without the permission of ILCO ORION.
Published: September 2003
Printed in Vittorio Veneto
by ILCO ORION
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy

INDEX
REFERENCE GUIDE .............................................................................................................5
GENERAL ..............................................................................................................................6
1TRANSPORT...............................................................................................................7
1.1 Packing ................................................................................................................... 7
1.2 Transport ................................................................................................................ 7
1.3 Opening the packing ............................................................................................... 7
1.4 Handling the machine ............................................................................................. 7
2MACHINE DESCRIPTION ..........................................................................................8
3WORKING PARTS ...................................................................................................10
3.1 Technical data ...................................................................................................... 11
3.2 Graphics ............................................................................................................... 11
3.3 Electrical circuit ..................................................................................................... 12
4ACCESSORIES PROVIDED ....................................................................................13
5MACHINE INSTALLATION and PREPARATION ....................................................14
5.1 Checking for damage ........................................................................................... 14
5.2 Environmental conditions ..................................................................................... 14
5.3 Positioning ............................................................................................................ 14
5.4 Description of work station ................................................................................... 14
6MACHINE REGULATION and REGISTRATION .....................................................15
6.1 Fitting and regulating the tools ............................................................................. 15
6.2 Adjustment ............................................................................................................ 15
6.3 Tracer springing .................................................................................................... 16
6.4 Spring system for LASER (Sidewinder) keys ....................................................... 17
6.5 Clamps ................................................................................................................. 19
7CUTTING OPERATIONS ..........................................................................................20
7.1 Fitting the keys ..................................................................................................... 20
7.2 Cutting dimple keys .............................................................................................. 20
7.3 Cutting the back .................................................................................................... 20
7.4 Cutting Laser (sidewinder) type keys ................................................................... 21
7.5 Cutting narrow-stemmed Laser (sidewinder) type keys ....................................... 22
7.6 Cutting keys for FICHET....................................................................................... 23
8MAINTENANCE ........................................................................................................24
8.1 Replacing the belt and adjusting tension .............................................................. 24
8.2 Replacing the light bulb ........................................................................................ 25
8.3 Checking and replacing the fuses ........................................................................ 25
8.4 Replacing the electronic board ............................................................................. 26
8.4.1 Replacing the circuit board ...............................................................................26
8.5 Replacing the motor ............................................................................................. 27
8.6 Replacing the clamp jaws ..................................................................................... 28
8.6.1 Replacing the left-hand jaw.............................................................................. 28
8.6.2 Replacing the right-hand jaw ............................................................................29
8.6.3 Replacing the left-hand mobile jaw ...................................................................30
8.6.4 Replacing the right-hand mobile jaw ................................................................31
8.6.5 Replacing the central jaw .................................................................................32
9WASTE DISPOSAL ..................................................................................................33
10 AFTER-SALES SERVICE ........................................................................................34
10.1 How to request service ......................................................................................... 34

Operating manual - English ECODRILL 2000 C/E
5
REFERENCE GUIDE
This manual has been produced to serve as a guide for users of the ECODRILL 2000 C/E key-cutting
machine. Read it carefully; it is essential if you wish to operate your machine safely and efficiently.
Consultation
The contents of the manual are divided into sections relating to:
- Transport and handling
- Checking the safety of the machine
- Proper use of the machine
- Maintenance
Technical terms
Common technical terms are used in this manual.
To assist those with little experience of keys and key-cutting, below is an illustration of the terms most
frequently used (fig. 1).
Fig. 1
1) Head
2) Rim
3) Stop
4) Stem
5) Tip
6) Back
7) Cuts
2
1
5
7
3
4
6
1
5
7
3
DIMPLE KEY LASER (SIDEWINDER) TYPE KEY
keys with holes of different
dimensions, depths, positions and
shapes.
LASER is the name given to the
special sidewinder milled keys.

ECODRILL 2000 C/E Operating manual - English
6
GENERAL
ECODRILL 2000 C/E has been designed in compliance to the European Community normative (CE).
From the design stage, risks for the operator have been eliminated in all areas: transport, regulation,
cutting and maintenance.
Further risks have been eliminated by means of protective devices.
The protective devices used are designed not to provoke further risks and, above all, they cannot be
ignored unless deliberately cut out. They do not hinder visibility of the work area.
A special adhesive label is attached to the machine warning the operator to use goggles during the
cutting operations, and this is strongly recommended in this manual.
The materials used to manufacture this machine and all its components are not hazardous.
Use
The ECODRILL 2000 C/E must be installed and used in the way laid down by the manufacturer.
If the key-cutting machine is used differently or for purposes different from those described in this
manual, the customer will forego any rights he may have over Ilco Orion. Furthermore, unforeseen
danger to the operator or any third parties may arise from incorrect use of the machine.
Negligence in the use of the machine of failure on the part of the operator to observe the instructions
given in this manual are not covered by the guarantee and the manufacturer declines all responsibility in
such cases.
It is therefore indispensable to read the operating manual carefully in order to make the best use
of the ECODRILL 2000 C/E sand benefit from its potential.
Instructions manual
The instructions manual provided with the machine is essential to its proper use and to carry out the
necessary maintenance.
We therefore recommend protecting the manual from damage in a safe sheltered place, easily to hand
for quick consultation.
Further risks
No further risks will arise when properly using the ECODRILL 2000 C/E.
Protection and safety precautions for the operator
The ECODRILL 2000 C/E key-cutting machine is entirely built in compliance to the Machine Directives.
The operations for which it has been designed are easily carried out with no risk to the operator.
The adoption of general safety precautions (wearing protective goggles) and observation of the
instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate.
ECODRILL 2000 C/E is designed with features which make it completely safe.
• Power supply
The machine is supplied with electricity by means of a grounded plug and differential switch.
•Electricpower
The machine is started up by means of the master switch.
• Start-up
The motor start switch activates the cutting tool.
• Illumination
The work area is illuminated by a lamp which operates when the machine is switched on with the master
switch.
• Maintenance
The operations to regulate, service, repair and clean the machine are structured in the simplest and
safest way possible. Parts that the operator can dismount cannot be incorrectly replaced therefore
avoiding any risks.
• Machine identification
The machine is provided with an identification label which includes the machine’s serial number (fig. 2).
Fig. 2
(*) see chap.9 WASTE DISPOSAL, page 33.

Operating manual - English ECODRILL 2000 C/E
7
1 TRANSPORT
The ECODRILL 2000 C/E key-cutting machine is easily transported and is not dangerous to handle.
The packed machine can be carried by one person.
1.1 Packing
The packing used for the ECODRILL 2000 C/E guarantees that the machine will travel safely without
danger of damage to it or its components.
The packing comprises four shells in expanded plastic in the machine is wrapped.
A strong outer cardboard box, the measurements of which can be seen in fig.3 and the plastic wrapping
protect the machine even over a long period of storage.
Fig. 3
1.2 Transport
The symbols on the outside of the packing box show the ideal conditions for transport.
Use of the packing box whenever the machine is transported will avoid knocks or bumps which could
cause damage.
1.3 Opening the packing
To remove the machine from the packing box:
1) cut the straps with scissors and remove.
2) open the box without damaging it as it may be used again (removals, despatch to the manufacturers
for repairs or servicing).
3) check the contents of the box, which should comprise:
- 1 ECODRILL 2000 C/E key-cutting machine packed in protective shells.
- 1 set of documents including: operating manual, spare parts list and guarantee.
- 1 connecting wire.
- accessories provided
4) remove the key-cutting machine from the protective shells .
1.4 Handling the machine
When the ECODRILL 2000 C/E has been unpacked, place it directly on its workbench.
This operation can be carried out by one person,
firmly holding the base and no other part, to lift and
carry the machine
.
440 mm
590 mm
555 mm
Keep dry This side up
Handle with care

ECODRILL 2000 C/E Operating manual - English
8
2 MACHINE DESCRIPTION
The ECODRILL 2000 C/E is an excellent quality, high precision key-cutting machine. It features great
versatility in cutting keys of different types without the need to replace the clamp or apply fixed adapters.
ECODRILL 2000 C/E cuts the following types of keys:
• dimple keys (with flat cuts)
• Laser (sidewinder) type keys
• keys for Fichet
dimple keys
keys for Fichet
(with adapter supplied)
Laser (sidewinder) type keys
Laser narrow-stemmed
(sidewinder) type keys

Operating manual - English ECODRILL 2000 C/E
9
High precision work is guarantee by the combination of the functional features on the ECODRILL 2000
C/E and all its components, such as:
• MOVEMENTS
The three axes move on ball guides which provide smooth running and easy sliding without play.
• SPRING SYSTEM FOR LASER (SIDERWIDER) KEYS
The machine is provided with a system which controls the run of the cross axis so that the operator can
easily trace the outline of the cuts along the key shaft.
• TRACER POINT SPRING SYSTEM
This system guides and facilitates self-centering of the cuts on dimple keys.
• ELECTROMECHANICAL SETTING
A precision electromechanical system ensures centesimal regulation of settings, made easier and
quicker by the warning lights on the machine key pad.
• PROTECTIVE SHIELD
A special transparent plastic shield prevents chippings from flying into the air.
•LAMP
Placed directly on the machine, it illuminates the work area.
• CENTESIMAL MICROMETRIC RING NUT
Ensures perfect depth alignment of the tools and makes it possible to adjust for defects on worn keys
with minute, controllable depth variations (+/- 0,02 mm).
• LEVERS AND KNOBS
Each lever and knob has been designed with dimensions, materials and positions which render grip and
movement extremely simple.
Materials and finish have been chosen according to the use of each part, especially:
- lever (I) for vertical carriage (Z axis)
ergonomic and provided with a locking mechanism which allows registration of the height of the cutter
assembly from the cutting surface, adapting this to the key (especially useful when cutting Laser
(sidewinder) keys) without a need for the operator.
- lever (C) X-Y axes
the lever which guides movement along the X-Y axes is ergonomic and makes precise, sensitive
movements due to a special joint with ball articulation and slide on ball guides.

ECODRILL 2000 C/E Operating manual - English
10
3 WORKING PARTS
Fig. 4
A - clamp carriage (X-Y axes)
B - left side jaw
B1- right side jaw
C - clamp carriage lever (X-Y axes)
E - left-hand jaw knob
E1- right-hand jaw knob
F - cutting tool
G - protective shield
H - clamp carriage locking knobs
I - vertical carriage lever (Z axis)
J-lamp
K - setting unit keypad
N - micrometric ring nut for regulating tracer point
O - regulating knob for Laser (sidewinder) key spring system
P - master switch
Q - motor start switch
S - tool drawer
T - tracer point
U - tracer springing ring nut
I
K
G
E1
P
B1
OS
H
B
E
C
J
T
F
Q
A
U
N

Operating manual - English ECODRILL 2000 C/E
11
3.1 Technical data
ELECTRICITY SUPPLY: 230V-50Hz / 100V-50/60Hz
MAXIMUM ABSORBED POWER: 1,1 Amp. 240 Watt / 1,7 Amp. 170 Watt
MOTOR: One-speed single phase
CUTTING TOOLS: Super rapid steel (HSS)
MOVEMENTS: on three axes
CLAMP: removable, with fixed and mobile interchangeable jaws
RUNS: X axis: 30 mm
Y axis: 50 mm
Z axis: 30 mm
DIMENSIONS: width: 350 mm depth: 420 mm height: 460 mm
MASS: Kg. 25
SOUND PRESSURE: Lp(A) = 78,2 dB(A)
3.2 Graphics
Fig. 5
THE USE OF PROTECTIVE GOGGLES
IS COMPULSORY

ECODRILL 2000 C/E Operating manual - English
12
3.3 Electrical circuit
The main parts of the electrical and electronic circuit on the ECODRILL 2000 C/E are listed below:
1) Plug with fuses
2) magnetic master switch
3) Motor switch
4) Motor
5) Lamp
6) Electronic board
7) Tracer contact
8) Cutter contact
9) Fuse 3,15A rapid (230V-100V)
Fig. 6
1
2
3
4
1
9
4
23
5
6
7
8
light blue
brown
light blue
brown
light blue brown
light blue brwon
light blue
brown
blue
M

Operating manual - English ECODRILL 2000 C/E
13
4 ACCESSORIES PROVIDED
A set of accessories is supplied for use with the machine or for servicing (tools, Allen keys and adapters).
The accessories include:
FUSE
code D309227ZZ
1 Amps delayed
code D420785BA
ADAPTER for Opel keys
2 pcs.
code DMK260080
CUTTING TOOL
for dimple keys
code D300223ZZ
3 mm
ALLEN KEY
code DMS200080J
SETTING PLATES
2 pcs.
FUSE (2 pcs)
code D309226ZZ
3,15
Amps rapid
code DMK260048
CUTTING TOOL
for Laser (sidewinder) keys
code DMK260047
TRACER POINT
for Laser (sidewinder) keys
1
2
3
4
5
8
9
10
code DMK260079
TRACER POINT
for dimple keys
11
613
714
12
code DMK260043
CUTTING TOOL
for dimple keys
code D300222ZZ
2,5 mm
ALLEN KEY
code DMK260044
TRACER POINT
for dimple keys
code D300225ZZ
5 mm
ALLEN KEY
code D426129RA
SETTING PINS
2 pcs.

ECODRILL 2000 C/E Operating manual - English
14
5 MACHINE INSTALLATION AND PREPARATION
The key-cutting machine can be installed by the purchaser and does not require any special skills.
The machine is supplied ready for use and does not need to be set up, except when changing to different
tools. However, some checks and preparation for use need to be carried out by the operator.
5.1 Checking for damage
The ECODRILL 2000 C/E key-cutting machine is solid and compact and will not normally damage if
transport, unpacking and installation have all been carried out according to instructions.
Notwithstanding, it is always advisable to check that the machine has not suffered any damage.
5.2 Environmental conditions
To ensure that the best use is made of the key-cutting machine, it is important to place it in a well-aired
area which is not too damp:
The ideal conditions for the machine are:
- temperature between 0 and 40°C
- relative humidity: approx 60%
5.3 Positioning
Place the machine on a horizontal surface, solid enough to support the weight of (30 Kg). The workbench
should be approx. 100-120 cm high to give easy access to the working parts of the machine.
Leave enough space around the machine (20-30 cm) to ensure good ventilation and room for
manoeuvre.
WARNING: ensure that the key-cutting machine voltage is suitable for the mains supply available, which
must be earthed and provided with a differential switch.
Fig. 7
5.4 Description of work station
The machine needs only one operator, who has the following controls at his/her disposal:
• master switch (P) placed on the back of the machine (fig.4, page 10).
• motor start switch (Q) (on the left-hand side of the machine).
• tool setting keypad (K).
• levers:
- lever (C) (fig.4, page 10) to move the clamp carriage.
- lever (I) to move the vertical carriage.
200mm
200mm
200mm

Operating manual - English ECODRILL 2000 C/E
15
6 MACHINE REGULATION AND REGISTRATION
Before carrying out cutting operations is necessary proceed with regulation about:
• fitting the tools and setting
• the cross spring for Laser (sidewinder) keys.
6.1 Fitting and regulating the tools
WARNING: make sure that the motor start switch (Q) (fig.4, page 10) is turned off.
Switch on the machine with the master switch.
Select the tools for the key to be cut and proceed as follows:
1) place the tracer point all the way into the left-hand sleeve and secure by tightening the grub screw (M)
(fig.8).
2) place the cutting tool all the way into the right-hand sleeve and secure by tightening the grub screw
(M1).
Releasing the tools
Unscrew the grub screw (M) and (M1) (fig.8) to remove the tracer point and cutting tool from the sleeves.
Fig. 8
6.2 Adjustment
Note: please note that before adjusting the machine you need to eliminate the tracer springing
(chap.6.3, page 16).
For carrying out adjustment, insert the cutter and tracer into their relative mandrils, block the bars (or 2
identical keyblanks) in the clamps and proceed as follows:
1) turn the machine on using the (P) main switch (fig.4, page 10).
2)
using the lever (I) lower the cutter-tracer unit so that the tracer touches the pin (fig. 9).
3) switch ON the lever of the front panel.
4) turn the adjustment knob (N) until the cutter touches its relative pin.
5) If both green leds switch ON simultaneously alignment is ok.
6) Switch off the lever.
7) the machine is adjusted and ready to duplicate.
Fig. 9
MM1
N
U

ECODRILL 2000 C/E Operating manual - English
16
6.3 Tracer springing
You can obtain the tracer springing simply by turning the inferior ring nut (U) (fig.10) of the
holder tracer spindle, while doing so, keep the superior ring nut (N) fixed. So, you have:
- to turn left to obtain the springing
- to turn right to eliminate it
Fig. 10
N
U
without springing springing

Operating manual - English ECODRILL 2000 C/E
17
6.4 Spring system for LASER (Sidewinder) keys
The machine ECODRILL 2000 C/E is provided with a system which controls the run of the cross axis so
that the operator can easily trace the outline of the cuts along the key shaft.
The spring system for Laser (sidewinder) keys is activated by means of the knob (O) (fig.11). It
determines lateral pressure on the part of the tools throughout the cutting operation; this makes it
possible for the operator to follow the outline of the cuts manually without having to exert cross pressure
on lever (C).
Fig. 11, fig.12, fig.13 and fig.14 show three examples of the use of the spring system:
1 central cutting 2 right-hand cutting 3 left-hand cutting
Fig. 11
Fig. 12
1 central cutting
O

ECODRILL 2000 C/E Operating manual - English
18
REGULATING THE SPRING
Loosen knob (O) (fig.11, page 17).
1 Central cutting :
take the cutter and tracer over the centre of the stems of the two keys (fig.11, page 17).
2 Right-hand cutting :
take the cutter and tracer over the keys, positioning them to the left of the stems (fig.13).
3 Left-hand cutting :
take the cutter and tracer over the keys, positioning them to the right of the stems (fig.14).
- Tighten knob (O) and carry out cutting operations.
Fig. 13
Fig. 14
2 right-hand cutting
adapter adapter
3 left-hand cutting

Operating manual - English ECODRILL 2000 C/E
19
6.5 Clamps
The clamps are provided with special key-locking jaws (fig.15) which can be easily changed if damage,
without replacing the whole clamp unit (see ch. 8.6, page 28).
Fig. 15

ECODRILL 2000 C/E Operating manual - English
20
7 CUTTING OPERATIONS
For complete safety during the cutting operations, take the following precautions:
• Always work with dry hands.
• Check that the machine is properly earthed.
• Wear protective goggles even if the machine is provided with a safety shield over the cutting
tool.
• Before starting the motor (switch Q), carry out the following operations:
a) place the keys in the clamps
b) install the tools and gauge them.
• Keep hands away from the cutting tool in motion.
7.1 Fitting the keys
1) Switch on the machine with the master switch.
2) take the clamp carriage towards the operator.
3) place the original key into the left-hand jaw and the keyblank into the right-hand jaw, paying attention
to the type of stop on the key.
7.2 Cutting dimple keys
1) turn on switch (P) (fig.4, page 10).
2) install the cutter and tracer point and gauge.
3) release the tracer point spring (ch. 6.3, page 16).
4) grip the levers (C) and (I) (fig.4) cut the key, first centering the tracer point on the hole on the
original key then taking the cutting tool up to the keyblank.
7.3 Cutting the back
If cuts are to be made on the back, place the key in a vertical position.
Fig. 16

Operating manual - English ECODRILL 2000 C/E
21
7.4 Cutting Laser (sidewinder) type keys
Before activating the start switch (Q) lower lever (I) close to the keys and regulate the spring
system for laser (sidewinder) keys (ch. 6.4) with knob (O).
1) start the cutting operation by activating switch (Q).
2) lower the spindle, cut the key and stop at the beginning of the cut (fig.17) (fig. 18).
• secure the spindle at this height by turning the lever (I) clockwise.
• carry out the cuts using only the left-hand lever (C).
Fig. 17
Fig. 18
EE1
bar