Mul-t-lock KC5 Mounting instructions
Computerized
Key-Cutting
Machine
KC5
TM
USER
OPERATION
MANUAL
KC5™ Key Cutting Machine
User Manual
Introduction
Safety Notices
System
Specifications
Packing and
Transportation
Functional
Description
Operator Manual
Maintenance
Appendixes
Table of Contents
1.Introduction
1.1. Message From Mul-T-Lock........................................ 4
1.2. Terms of Usage............................................................ 5
1.3. User Language Translation ....................................... 6
2.Safety Notices
2.1. Safety Notes in Manual.............................................. 7
2.2. Safety Notes for Machine Use.................................. 8
2.3. Safety Notes Concerning Maintenance................. 10
3.System Specifications
3.1. General.........................................................................11
3.2. Machine Layout and Measurements...................... 12
3.3. Weight.......................................................................... 14
3.4. Service Environmental Requirements................... 14
3.4.1. Site Requirements and Arrangement ................ 14
3.4.2. Wall Sockets Power Supply Requirements........ 14
3.4.3. Telephone Lines................................................ 14
3.4.4. Internet Wall Socket.......................................... 15
3.4.5. Working Surface for the Machine:..................... 15
3.4.6. Vibration ........................................................... 15
3.4.7. Lighting............................................................. 15
3.4.8. Electric Cable (plug and socket)....................... 16
3.5. Machine Label............................................................ 17
3.6. Noise Level................................................................. 17
4.Packing and Transporting
4.1. Safety Notes for Lifting and Transport.................. 18
4.2. Packing Instructions.................................................. 19
4.3. Packing Dimensions.................................................. 24
4.4. Transporting Instructions.......................................... 25
4.5. Uncrating..................................................................... 27
4.6. Installation Area Features........................................ 28
4.7. Receiving Inspection................................................. 28
5.Functional Description
The Major Parts of the Machine............................................................................30
5.1. General............................................................................................................31
5.1.1. PLC ......................................................................................................31
5.1.2 HMI LCD and Keypad...........................................................................31
5.2. General Machine View..................................................................................32
5.3. X and Y Unit: ..................................................................................................36
5.4. Z Station:.........................................................................................................37
5.4.1. BDLC driver..........................................................................................37
5.5. Metal Chips Drawer.......................................................................................39
5.6. Spindle Motor and Cutting Tools Station ..................................................40
5.7. Change Cutting Tools....................................................................................41
5.7.1 The tool replacement procedure ...........................................................43
5.8. Key Clamp.......................................................................................................44
5.9. Magnetic Card Reader..................................................................................45
5.10. HMI LCD and Keypad...................................................................................46
5.11. Safety Door.....................................................................................................47
5.12. Door Open Warning ......................................................................................49
5.13. Power Supply Socket and Main Switch....................................................50
5.14. Main Fuse and Fuse Replacement............................................................51
5.15. Machine Key Switch......................................................................................52
5.16. USB Plug Unit ................................................................................................53
5.17. Machine Ventilation.......................................................................................54
5.18. Machine Axes and Directions......................................................................55
5.19. Electrical Connections..................................................................................56
Table of Contents
KC5™ Key Cutting Machine
User Manual
Introduction
Safety Notices
System
Specifications
Packing and
Transportation
Functional
Description
Operator Manual
Maintenance
Appendixes
6.Operator’s Manual
6.1. Operator Training and Certification........................ 57
6.2. Machine Emergency Stop........................................ 59
6.3. Operator Manual........................................................ 60
6.3.1. General............................................................. 60
6.3.2. Preliminary Steps.............................................. 61
6.4. LCD Display................................................................ 62
6.4.1. The AUTO Option ............................................. 64
6.4.2. The MANUAL Option ........................................ 66
6.4.3. Profiles ............................................................. 67
6.4.4. The SERVICE Option........................................ 71
6.4.5. The OFFSET Option......................................... 72
6.4.6. The TOOL CAL (Calibration) Option.................. 74
6.4.7. The UPGRADE Option...................................... 75
6.4.8. The ETC Option................................................ 77
6.4.9. The COUNTERS Option ................................... 78
6.4.10. The TWO SIDES Option................................... 79
6.4.11. The two sides AUTO Option ............................. 80
6.4.12. The two sides MANUAL Option......................... 81
6.4.13. The TOOL CHANGE Option.............................. 82
6.4.14. The Machine Information Screens .................... 83
6.5. Turning the Machine OFF........................................ 84
7.Maintenance
7.1. General........................................................................ 85
7.2. Daily Check................................................................. 86
8.Appendix
8.1 Spare Parts List.............................................................. 87
8.2 Data Record Table for Axis OFFSET......................... 89
8.3 Depth Measurements for Key Combination Cut...... 90
8.4 Troubleshooting.............................................................. 91
8.5 Motor Belt Tensioning ................................................... 94
– 4 –
1. Introduction
This manual is intended as a practical guide for correct, safe use and proper maintenance of
the machine.
It is important to read the manual carefully before operating the machine. Doing so will ensure
proper use of the machine and prevent possible accidents during work or maintenance.
As Mul-T-Lock continuously develops its machines to their maximum potential. Although this
manual was completely up to date when issued, it is subject to future changes.
The machine serial number is marked on the machine label.
1.1. Message From Mul-T-Lock:
The KC5 represents a new generation of high efficiency key cutting machines. As a world
leader in the field, Mul-T-Lock takes the pride in providing the best quality, and the most
efficient high security products, for locksmiths.
The KC5 offers fully automated CNC technology with three separates cutting axes. The
machine is delivered to your premises fully pre-programmed and calibrated. It is suitable for
cutting MT5®keys and also compatible for cutting of all previous platforms of Mul-T-Lock key
types.
– 5 –
KC5™ Key Cutting Machine
User Manual
Safety Notices
Functional
Description
Operator Manual
Maintenance
Appendixes
Introduction
Packing and
Transportation
System
Specifications
1.2. Terms of Usage
The right and license to cut keys for Mul-T-Lock®Ltd. products is
subject at all times to the terms in the agreement between the buyer
of the KC5 Key Cutting Machine and Mul-T-Lock®Ltd. Refer to your
agreement.
Example of a magnetic card
MAGNETIC DUPLICATION KEY CARD
– 6 –
Introduction
1.3. User Language Translation
After receiving the machine from Mul-T-Lock®Technologies Ltd., the user may contact
Mul-T-Lock Service Department and ask for permission to translate this manual into the user’s
language.
The applicant will fill in and send the form obtained from the Mul-T-Lock®Technologies Ltd.
The form is simple and only concerns copyrights. After receiving the filled and signed form, we
will send to the buyer the file of this manual in two formats by e-mail: a PDF file for the record
and Microsoft Word file for editing.
When the translation complete, the user must return by mail two copies: (a) file.doc (c) color
printed file (hardcopy), and, if possible, another (c) copy of the PDF file.
– 7 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
Safety Notices
System
Specifications
2. Safety Notices
2.1. Safety notes in manual
The following safety notations are used in this manual:
CAUTION
Operating procedures conditions, which must be strictly observed to
prevent damage or destruction of the equipment.
WARNING
Operating procedures and conditions, which must be strictly observed to
prevent personnel injury or death.
It is therefore essential to read this manual carefully before proceeding
with start up, use, maintenance or any other machine jobs.
The machine is equipped with all the safety devices necessary to ensure
risk-free use under standard conditions.
Machine installation, maintenance and adjustment must be carried
out in accordance of all safety standards and in observance of all the
precautions deemed necessary for each task.
The operator must be qualified. He must have expert machine
knowledge and must have read this manual.
Extreme care must be taken to ensure constant operator safety
standard.
We advise strict observance of the work safety standard as defined by
the relative authorities in each nation.
The manufacturers accept no responsibility for damage to persons or
objects resulting from noncompliance of safety standards.
– 8 –
Safety Notices
2.2. Safety Notes for Machine Use
WARNING
The following safety practices must be complied with:
• CAUTION and WARNING notices posted on the machine and safety notes in this manual.
• Only qualified and certified personnel may operate the machine and/or perform maintenance
on the machine. Operating personnel must not remove covers or panels.
• Do not start the system if any safety cover is missing. Safety covers are located around the
machine and around cutting tools.
• Ensure that all control panels and electrical panels are covered.
• When carrying out maintenance of the system, post highly visible warning signs.
• Before turning on the system, the operator must carry out the following steps:
• Perform a visual examination of the system’s components (e.g. ensure that the equipment is
properly placed; view any messages on the display, etc.).
• Verify that the system is not undergoing maintenance.
• The operator must always verify through direct tests that the emergency commands of the
system are in perfect working order.
• Never leave the machine unattended when in use, except in cases where this is allowed.
• During a pause in the work cycle, switch OFF the machine. During prolonged pause, turn the
main switch to OFF and remove the machine key from the switch and take it with you.
• The machine may stop during work cycle for any number of reasons. Whenever this happens
and the situation requires access to the inside of the machine containing the electrical
equipment and electrical connection, always set the general switch to OFF.
• The safety door is attached to a safety sensor. It is unable to open covers while the machine
is in operation. The covers can only be opened after the machine stops running.
• MOVING PARTS – Moving parts may causes bruises and cuts.
– 9 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
Safety Notices
System
Specifications
WARNING
Keep away from moving parts.
• Do not wear rings, wristwatches, or other jewelry while working with
live electrical circuitry.
• No smoking or food is permitted in the working area.
• Replace and close all safety shields after completing set-up,
troubleshooting, and maintenance procedures.
• Report any unsafe conditions to the supervisor.
• Secure electrical wires and cables to prevent damage.
• Ensure that all personnel know the main power switch and main
emergency switch locations and how to react in case of an electrical,
mechanical, or other emergency.
• Place approved types of fire extinguishers near the equipment.
• Arrange the material to be worked in a rational manner so that it does
not hinder the work cycle.
WARNING
• HOT SURFACES: Some motors might have hot surface after running.
Unauthorized personnel may not remove covers. If a cover was
removed do not touch.
– 10 –
2.3. Safety Notes Concerning Maintenance
WARNING
Do not allow unauthorized personnel to carry out repairs, maintenance or tool replacement
tasks. Carefully read the user and maintenance instructions manual before beginning or using
the machine, or effecting machine or plant maintenance or tool replacement tasks.
Use only Mul-T-Lock original spare parts, cutting tools and accessories supplied with the
machine or purchased directly from Mul-T-Lock®Technologies Ltd.
To avoid getting caught in the moving parts area, do not repair, adjust or replace tools in the
machine while in it is operation and/or the main switch is ON.
Turn off the machine according to the procedures laid down in the user and maintenance
instruction manual before carrying out other tasks.
Do not use matches, cigarette lighters, or torches as a means of lighting during work on the
machine.
Tool replacement in this manual is part of the Functional Description of this manual.
Safety Notices
– 11 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
System
Specifications
Safety Notices
3. System Specifications
3.1. General
This manual describes the working procedures for the KC5 - Key
Cutting Machine. All machine components, their functional correlation,
power requirements, and other relevant descriptions are detailed and
illustrated here to provide the operator with a thorough understanding
of the system and of the proper maintenance and safety procedures,
thereby minimizing machine downtime.
The machine is specially designed and manufactured by Mul-T-Lock
Machinery Ltd., for customers of Mul-T-Lock®Technologies Ltd.
The machine is specially designed for the cutting of all key platforms of
Mul-T-Lock®Technologies Ltd.
The machine consists of three axis that work simultaneously. Each axis
of the machine carries out part of the key cutting process according to
the code from the PLC/card reader.
– 12 –
3.2. Machine Layout and Measurements
System Specifications
D = 340
W = 525
Top view
– 13 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
System
Specifications
Safety Notices
Front view
H = 360
– 14 –
System Specifications
3.3. Weight
Machine (net) weight: 32 Kg.
Packing box (tare) weight: 7 Kg.
Packed unit weight: 39 Kg.
3.4. Service Environmental Requirements
We recommend preparing the working site in advance. Some requirements include future
arrangements and we recommend carrying out basic preparation for installation before the
machine arrives, especially any work that generates dust.
3.4.1. Site Requirements and Arrangement
The machine should be installed in a working area that provides adequate space for the
operation and maintenance of the machine.
3.4.2. Wall Sockets Power Supply Requirements
• The machine needs one wall electric socket.
• Power supply requirements: 1 PHASE – 220/110 Volts, 6.3/10 Ampere, 50/60 Hz.
• An electrician should check the ground in each socket.
• If it is necessary to connect a computer and additional light, two more electric sockets will be
required.
• Prepare a minimum of three wall sockets.
3.4.3. Telephone Lines
The site should include at least one telephone line for speaking with service personnel.
– 15 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
System
Specifications
Safety Notices
3.4.4. Internet Wall Socket
It is highly recommended that the site shall include an Internet socket
for connecting a personal computer (PC) for online remote services
purposes. Internet service can be via telephone line or TV cable.
Consult your vendor.
3.4.5. Working Surface for the Machine
The machine should be placed on a workbench. A desk or a table
can be used; both must be rigid, stable and able to carry a load of
approximately 150 kg. Load the table and check its rigidity. To make
the table rigid, it is possible to attach the table top to a wall. Use a
table of suitable height of about 75 cm if the operator will operate the
machine from a seated position, or at a height of about 1 meter if the
operator will operate the machine from a standing position.
Calculate the tabletop surface dimensions on the basis of size of the
machine, the size and type of the computer, and other criteria. Do not
block the ventilation shields at side of the machine.
Leave 200 mm of free space for ventilation around machine, especially
on the right-hand side.
3.4.6. Vibration
The machine vibration is low and no special arrangement is needed. If
the operator fills any abnormal vibration, he should stop the machine
immediately.
3.4.7. Lighting
The machine has small internal lights. This light is suitable to operate
the machine for key cutting. For other tasks on the machine, such
as cleaning or tool replacement, a stronger light is needed. Install a
regular 100 Watt bulb light about 1 meter above the machine or add
suitable strong light nearby.
– 16 –
3.4.8. Electric cable (plug and socket)
Electric cable/cord is supplied with the machine. The cable is a regular 10 Ampere cable.
Consult your local electrician for any advice.
The electric cable/cord socket side
System Specifications
– 17 –
KC5™ Key Cutting Machine
User Manual
Functional
Description
Operator Manual
Maintenance
Appendixes
Packing and
Transportation
Introduction
System
Specifications
Safety Notices
3.5. Machine Label
• Check the serial number of the machine. This number is used for
authorized upgrade.
• Check the current: 230V/50HZ or 110V/60HZ.
3.6. Noise Level
The machine noise level is low and normal.
The level is below 80 dbA.
The use of ear protection is not mandatory, but ear protection is
recommended for prolonged usage.
– 18 –
4. Packing and
Transporting
4.1. Safety Notes for Lifting and Transport
WARNING
The manufacturer bears no responsibility for any damage to objects or persons caused
by non-compliance with the applicable safety standards in force relating to the lifting and
movement of material within the user’s factory.
Machine transfer and truck loading must only be carried out with the appropriate equipment as
described in the Packing & Transporting section.
Always act with extreme care to prevent personal injury or damage to the machine or its
individual parts.
Personnel must keep clear from the suspended load and, in any case, keep out work areas
where cranes, forklift trucks, and other lifting/handling equipment are in use.
The transit lanes inside the factory where the machine is to be installed must be kept clear.
The floor must be kept clean and free from any obstacles, which might make the forklift truck or
crane to “jump”.
The load must always be securely fixed to a load-bearing part of the lifting and transport
equipment, thus preventing any movement whatever the cause.
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KC5™ Key Cutting Machine
User Manual
Introduction
Safety Notices
System
Specifications
Packing and
Transportation
Functional
Description
Operator Manual
Maintenance
Appendixes
Introduction
System
Specifications
Safety Notices
4.2. Packing Instructions
The machine is packed into cardboard crates tailored to accommodate
the machine’s dimensions. After unpacking the machine, store all
packaging items for repacking the machine for shipment to the factory in
the future, if necessary.
The machine stands on the bench, which includes shock absorbent
material to protect the machine during transport.
The machine is attached to a bench with four metal brackets. Use two
screws for each bracket.
Table of contents
