ilco 009B User manual

009B
OPERATION MANUAL
Tubular Key Duplicator

009B Operation Manual
2
The 009B Tubular Key Machine is a precision tool and should be operat-
ed with care. Please read this instruction manual before duplicating any
keys. This manual gives step by step instructions on how to duplicate
tubular keys and includes a section on how to adjust the 009B.
CONTENTS
How to Duplicate a Key ........................................................
How to Replace the Cutter ...................................................
How to Make Cutter Adjustments .........................................
Limited Warranty ..................................................................
The 009B is designed for duplicating the Ilco® 1137B tubular style key.
Examine the diagram and familiarize yourself with the Tubular Key
Machine. Knowing the names for the basic parts of this machine will
make instructions more meaningful and easier to understand.
Parts
A Motor
B Cutter Adapter
C Cutter
D Chuck Nut (Closing Nut)
E Clear Shield
F Guide
G Main Shaft
H Shield Knob
I Power Switch
J Key Gauge
AJ
I
H
G
F
E
D
C
B

Operation Manual 009B
3
How to Duplicate a Key
1. Place original key (key being duplicated)
on end of shaft to right of machine. (See
Figure A)
2. Insert key blank (uncut key) into chuck end
of main shaft making certain that the key
blank indexing is in the same direction as
the original key.
Index (nib) on both key blank and original
must face up. (See Figure B)
The key blank should be bot-
tomed in the chuck. Partially
tighten chuck.
3. Rotate Key Gauge into the “load”
position, and then loosen the
Main Shaft Closing Nut to allow
the key blank to position against
the face of the Setting Gauge.
Tighten the Closing Nut to re-
tain the key blank in this posi-
tion. (See Figure C) Now ro-
tate the Key Gauge back into its
“rest” position.
4. Swing the Clear Safety Shield
into position above the cutter
as shown in Figure D. Turn the
Power Switch “ON”.
5. Advance the original key and at
the same time rotate so that the
rst cut on the original key lines
up with the guide. Advance key slowly until the guide bottoms rmly in
the cut. Back off slowly and rotate key to next cut. Repeat this process
until all cuts are completed. (See Figure E)
6. Turn power switch “OFF” and swing clear shield to “load” position.
7. Loosen chuck closing nut and remove key.
Caution: In order to prolong cutter life, a slow steady movement should
be maintained while cutter is in contact with key blank. We do not recom-
mend cutting steel key blanks as cutter life will be dramatically reduced.
Fig. A
Fig. B
Fig. C
Fig. D Fig. E

009B Operation Manual
4
How to Replace the Cutter
The cutter should be replaced when cuts begin to look rough or undue
force is required for the cutter to cut the key blank. Do not attempt to cut
keys when the cutter is dull. The proper cutter for use on the 009B is Ilco®
part #16TW.
Caution: Machine should be unplugged when replacing the cutter
or making any cutter adjustments.
1. Place an 1137B key blank on shaft to right of machine.
2, Insert a second blank into the
Main Shaft chuck until bottomed
out ush with the face of the
chuck.(See Figure F) Tighten
closing nut lightly to retain in this
position.
3. Rotate Key Gauge into the
“load”position, and then loosen
the Main Shaft Closing Nut to
allow the key blank to posi-
tion against the face of the Key
Gauge. Tighten the Closing
Nut to retain the key blank in
this position. (See Figure G)
Now rotate the Key Gauge back
into its “rest” position. See Figure
.
4. Remove dull cutter by loosening
cutter adapter set screw and removing
cutter. (See Figure H)
5. Insert new cutter (part #16TW), leaving
approximately 1/2 inch of the cutter ex-
posed. (Don’t tighten set screw yet.)
6, Holding key blank in place on end of
shaft, advance key toward cutter until
it comes to rest against the guide. Dur-
ing this process, the key blank which
you have placed in the chuck will have
pushed the cutter into proper position.
(See Figure I)
7. Tighten cutter adapter set screw to se-
cure the cutter in this position, taking
care not to disturb the positioning of
the cutter. The machine is now ready
for use.
Fig. F
Fig. G
Fig. H
Fig. I

Operation Manual 009B
5
How to Make Cutter Adjustments
Cutter Height (Wall Thickness)
Check cutter height by cutting sample key and
measuring the distance across the cuts with dial
calipers.
If this dimension is not within the proper range, the
cutter height must be adjusted. This dimension may
range from .323 inch to .328 inch (A). (See Figure
J)
If adjustment is needed:
1. Unplug the machine!
2. Using a Phillips type screwdriver, re-
move the four rubber feet from the
bottom of the machine to release the
machine’s bottom cover plate. (See
Figure K)
3. Slightly loosen the motor elevation
locking screw (A)*. (See Figure L)
* Very Important! Do not loosen or
adjust screws identied in the photo
as “X”
• If cuts are not deep enough (mea-
surement more than ,328”), back off (counter-clockwise) both
adjustment screws (B). Be certain to back off both screws ex-
actly the same amount. Each 1/16 turn will lower the cutter
approximately .010 inch.
• If cuts are too deep (measurement less than .323”), advance
(clockwise) both adjustment screws (B). Be certain to advance
both screws exactly the same amount. Each 1/16 turn will
raise the cutter approximately .010 inch.
4. Tighten motor elevation locking screw (A). Cut another key. Measure
distance across the cuts and repeat steps given above if necessary.
5. Reposition bottom cover and re-attach rubber feet.
Tip of tubular key
Fig. J
Fig. K
Fig. L
X
X
B
A
B
X
X

009B Operation Manual
6
Limited Warranty
Kaba Ilco warrants to the original buyer of any new model 009B 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 aris-
ing from the quality manufacture of the machine or from defective materi-
als or components, during a period of one year from the date of shipment
of the machine by Kaba Ilco, provided 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, in its discretion, elect to refund the
purchase price allocable 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
subjected to improper installation, improper use, improper or inadequate
maintenance, negligence, of any unauthorized modication or alteration
is made to the machine not operated in accordance with Kaba Ilco’s
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 to any machine, product, or
component thereof shall be effective only if and for so long as the buyer
complies with all payment obligations pursuant to the buyer’s accepted
and acknowledged order. Failure to meet such payment obligations pur-
suant to the buyer’s accepted and acknowledged order. Failure to meet
such payment obligations shall void all warranties and not extend the
period of time for which such machine, product or 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 war-
ranty of condition, expressed or implied including without limita-
tion merchantability, tness for a particular purpose or latent de-
fects. 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, including negligence, exceed
the purchase price of the defective machine, nor shall Kaba Ilco be liable
for an personal injuries, property damage or consequential damages.
Use only genuine Kaba Ilco replacement parts on this machine.

Operation Manual 009B
7

Kaba Ilco Corp.
400 Jeffreys Road • Rocky Mount, NC 27804
Phone [phone] • Fax [phone]
www.kaba-ilco.com
Code No. 125146