Silca D429724XA User manual

®
D429724XA
vers. 4.0
Operating manual
Technica
Technica

(c) 2005 SILCA S.p.A. - Vittorio Veneto
This manual has been drawn up by
SILCA S.p.A.
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 written permission of
SILCA S.p.A.
Edition: september 2005
Printed in
Vittorio Veneto
by SILCA S.p.A.
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy

INDEX
GUIDE TO THE MANUAL .........................................................................................................1
GENERAL .................................................................................................................................2
1 MACHINE DESCRIPTION ..........................................................................................4
1.1 Main Characteristics ...........................................................................................4
1.2 Working parts .....................................................................................................5
1.3 Technical Data ...................................................................................................6
1.4 Accessories provided .........................................................................................6
1.5 Safety .................................................................................................................7
1.6 Electric circuit .....................................................................................................7
2 TRANSPORT ..............................................................................................................8
2.1 Packing ...............................................................................................................8
2.2 Unpacking ..........................................................................................................8
2.3 Machine handling ...............................................................................................8
3 MACHINE INSTALLATION AND PREPARATION ....................................................9
3.1 Checking for damage .........................................................................................9
3.2 Positioning ..........................................................................................................9
3.3 Description of work station .................................................................................9
3.4 Environmental conditions ...................................................................................9
3.5 Graphics .............................................................................................................9
4 REGULATION AND USE OF THE MACHINE .........................................................10
4.1 Micrometric tracer point ....................................................................................10
4.2 Tracer point spring ...........................................................................................10
4.3 Right-hand clamp movement ...........................................................................10
4.4 Checking and gauging ......................................................................................11
4.4.1 A XIAL GAUGING ON BIT / DOUBLE BIT KEYS ...............................................................11
4.4.2 D EPTH GAUGING ...................................................................................................12
4.5 Cutting operations 1............................................................................................3
4.6 Cutting bit and double bit keys .........................................................................13
4.6.1 C UTTING SHORT KEYS ...........................................................................................14
4.6.2 C UTTING DOUBLE FEMALE BIT KEYS .......................................................................14
4.7 Cutting keys with centre stop ...........................................................................15
4.8 Cutting pump keys ............................................................................................16
5 MAINTENANCE ........................................................................................................17
5.1 Cleaning ...........................................................................................................17
5.2 Carriage replacement .......................................................................................17
5.3 Replacing the tracer point ................................................................................17
5.4 Replacing the cutter .........................................................................................18
5.5 Replacing the brush .........................................................................................18
5.6 Belt replacement and/or tensioning - Belt tightening pulley replacement .........19
5.6.1 B ELT TIGHTENING PULLEY REPLACEMENT ..............................................................20
5.7 Replacing the master switch ............................................................................20
5.8 Replacing the fuses ..........................................................................................21
5.9 Replacing the light bulb ....................................................................................21
5.10 Clamp spring replacement ...............................................................................21
5.11 Condenser (motor) and/or Feeder (lamp) replacement ....................................22
5.12 Speed commutator ...........................................................................................23
5.12.1 R EPLACING THE COMMUTATOR ..............................................................................23
5.13 Motor replacement ...........................................................................................24
6 DECOMMISSIONING ...............................................................................................26
7 AFTER SALES SERVICE ........................................................................................27
7.1 How to request service .....................................................................................27

Technica Operating manual - English
Copyright Silca 2005 1
GUIDE TO THE MANUAL
This manual has been produced to serve as a guide for users of the TECHNICA key-cutting machine. Read it
carefully; it is essential if you wish to operate your machine safely and efficiently
.
CONSULTATION
- Description of machine ......................................................................................................... Chapter 1
-
Transport and handling ......................................................................................................... Chapters 2-3
- Regulation and use ................................................................................................................ Chapter 4
- Maintenance ........................................................................................................................... Chapters 5-6
Technical terns
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
1) Head
2) Rim
3) Tip
4) Bit
5) Shoulder
6) Side
1
2
4
35
6
5
6
6
4
5

Operating manual - English Technica
2 Copyright Silca 2005
GENERAL
TECHNICA 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.
Risks have been eliminated by means of protective devices.
The use of protective goggles is compulsory during cutting operations, as indicated on the machine itself and in this
manual.
The materials used to manufacture this machine and all its components are not hazardous
.
USE
The TECHNICA 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
Silca . 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
TECHNICA and 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
• when the machine is in operation only the operator should be close
to it as the moving tools are partially exposed and metal swarf is
generated by machining .
•
before activating the master switch (A) (fig. 5, page 5), the operator
must make sure that the cutter motor starting switch is in position
"0" (fig. 38, page 23).
•
when the machine is in operation, area "A" (fig. 2) can be hazardous
for the operator and any third parties in the proximity of the key-
cutting machine if the warnings and precautions given in this
manual are not observed .
Fig. 2
Protection and safety precautions for the operator
The TECHNICA 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.
TECHNICA is designed with features which make it completely safe .
• Power Supply
The key-cutting machine must be supplied with electricity. The plug must be earthed .
• Electric power
The machine is started up by means of the master switch .
• Start-up
The speed commutator activates the machine and allows selection of the required speed.
• 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
.
A
A

Technica Operating manual - English
Copyright Silca 2005 3
• Machine identification
The machine TECHNICA is provided with an identification label which includes the machine’s serial number (fig. 3).
Fig. 3
(*) see Ch. 6 "DECOMMISSIONING", page 26.

Operating manual - English Technica
4 Copyright Silca 2005
1 MACHINE DESCRIPTION
Fig. 4
1.1 Main Characteristics
•KEY-CUTTING UNIT WITH CARRIAGE
The key-cutting unit contains the working parts of the TECHNICA key-cutting machine, which carry out reading
and cutting of the original key and the necessary finishing off. The working parts are
:
Cutter:
The cutter is the part of the key-cutting machine used to cut keys. It is in super rapid steel (HSS) and is protected
by a special shield to guarantee safety for the operator.
Tracer point unit:
The tracer point is dedicated to reading the cuts on the keys. It is easily regulated (depth and axial gauging).
Carriage:
The carriage comprises a clamp unit for cutting bit-double bit and pump keys.
The carriage movement is horizontal on 2 axes (X-Y) and controlled by means of the lever (L) (fig. 5, page 5).
The knob (R) is used for rounding off bit and double bit keys.
Clamps for bit-double bit and pump keys:
The clamps comprise two self-centering jaws that ensure perfect grip on the stem of bit-double bit and pump keys
(with round or square stems).
•MASTER SWITCH
The master switch is located on the bottom left-hand side of the lamp.
•MOTOR ON SWITCH /SPEED COMMUTATOR
On the top left-hand side there is a switch for starting the motor at the required speed.
•ILLUMINATION
The lamp is fixed and it illuminates the work zone to be used perfectly.

Technica Operating manual - English
Copyright Silca 2005 5
1.2 Working parts
Fig. 5
A - master switch
A1- main plug with fuses
B - motor switch / speed commutator
C - cutter
C1- cutting tool housing
D - tracer point
D1- tracer point spring locking knob
D5- ring nut locking knob
E - tracer point support
F - clamp carriage locking levers
G - carriage locking knob
H - motor
I - top cover
L - clamp carriage traverse lever
M - fixed clamp for bit/double bit and pump keys
M1- mobile clamp for bit/double bit and pump keys
P - fixed clamp locking lever
P1- mobile clamp locking lever
R - lever for movement of mobile clamp
S - locking lever for mobile clamp
T - lamp
U - brush
V - chippings tray
A
B
C
C1
D
E
F
V
H
L
M
M1
P
P1
R
S
TI
U
G
D1
D5
A1

Operating manual - English Technica
6 Copyright Silca 2005
1.3 Technical Data
MOTOR: 2 speed single phase , 230V-50Hz
CUTTER: ø 80 x 1,5 x 22 super rapid steel (HSS)
CUTTER SPEED:
speed 1 = 320 rpm (for steel keys )
speed 2 = 650 rpm (for brass keys )
MOVEMENTS: by means of lever and rectified carriage shaft
CLAMPS:
hardened steel
ILLUMINATION: neon lamp 230V d.c.
DIMENSIONS: width: 440 mm depth: 500 mm height: 420 mm
WEIGHT: Kg. 32
SOUND PRESSURE: Lp (A) = 91 dB (A) max. [brass keys]
Lp (A) = 86,5 dB (A) max. [iron/steel keys]
1.4 Accessories provided
Tools pouch
D401198ZZ
4 mm allen key
D300224ZZ
19 mm spanner
D300783ZZ
Centring template
1 pc.
D428361BA
5 mm allen key
D300225LR
Cutting tool release
bar
D400754BA
2 mm allen key
D300221ZZ
6 mm allen key
D300226ZZ
fuse
5 Amp - rapid
D310788ZZ
2,5 mm allen key
D300222ZZ
Setting pins
D200470ZZ
mm allen key
3 mm
D300223ZZ
Stop pins for
FIAM keys
2 pcs.
D400753ZZ

Technica Operating manual - English
Copyright Silca 2005 7
1.5 Safety
•CUTTER MOTOR PROTECTION
ATTENTION: the cutter motor is protected from overheating by a device (inside the motor) that stops it when it
reaches a dangerous temperature
.
This condition can occur when the machine motor is left on continuously, with high ambient temperatures
or in severe working conditions. If the cutter motor overheats it cuts out automatically. In such cases
proceed as follows:
a) turn off the master switch (A).
b) let the motor cool for at least 2 hours then use the machine normally.
•START-UP
The master switch (A) has a safety function that prevents untimely start-up when voltage returns after a cut-out.
1.6 Electric circuit
1) Main plug with fuses
2) Safe main switch
3) Terminal board
4) Lamp reactor
5) Neon lamp
6) Cutter motor condenser
7) Commutator
8) Motor cut-out safety switch
9) Cutter motor
10)Motor ventilator
()
()
2
1
3
6
8
10
9
7
5
4
MV
0
12
brown
black
brown
blue
black
blue
brown
blue
brown
blue
yellow/green
WVU 3 2 1
-
-
7
8

Operating manual - English Technica
8 Copyright Silca 2005
2 TRANSPORT
The TECHNICA key-cutting machine is easy to transport and is not hazardous to handle.
The packed machine should be carried manually by at least 2 persons.
2.1 Packing
The packing for TECHNICA is designed to ensure safe transportation and protect the machine and all its parts .
It comprises a pallet base (b) to which the machine is attached, and a cardboard box as a cover (a) (fig. 6).
The machine is fixed to the base with screwed down brackets to hold it firm during transport and protect it .
The closed packing is held in place by two straps which hold the cardboard box firmly on the pallet .
Symbols are printed on the outside of the cardboard box to give instructions and warnings for transportation.
Fig. 6
2.2 Unpacking
To remove the machine from the packing box :
1)
cut the straps with scissors and remove .
2)
raise the top part of the cardboard box .
3) loosen the screws on the front and rear brackets holding the machine on the pallet.
4) use the special spanner to loosen the nuts on the feet by a couple of turns.
5)
remove the metal brackets and tighten the nuts on the feet .
6)
check the contents of the box, comprising :
-1
key-cutting machine
- 1 set of documents, including: operating manual, spare parts list and guarantee
- 1 power cable
-1
tools pouch
2.3 Machine handling
When the TECHNICA key cutting machine has been unpacked, place it directly on its workbench; this operation
should be carried out by at least two people. Take care to lift the machine firmly holding the base, and no other
part.
a
b
Keep dry This side up Don’t use
Handle with care

Technica Operating manual - English
Copyright Silca 2005 9
3 MACHINE INSTALLATION AND PREPARATION
The key-cutting machine can be installed by the purchaser and does not require any special skills; some checks
and preparation for use operations have to be carried out by the operator.
3.1 Checking for damage
TECHNICAis solid andcompact and willnot normally damageif transport, unpackingand installationhave all been
carried out according to the instructions in this manual. However, it is always advisable to check that the machine
has not suffered any damage.
3.2 Positioning
1) Place the machine on a horizontal surface,
solid enough to take its weight.
2)
to facilitate operation the workbench height
should be about 100 cm
.
3) werecommend leaving clearanceof at least20
cm behind the machine and on each side to
ensure proper ventilation and handling.
4)
check that the weight of the machine is evenly
distributed over the four feet
.
5)
connect the machine power supply cable to the
mains
.
ATTENTION: ensure that the machine voltage is the same
as that of the mains, which must be properly
earthed and provided with a differential
switch.
Fig. 7
3.3 Description of work station
The machine needs only one operator, who has the following controls at his/her disposal:
• Master switch (A) located on the bottom left-hand side of the lamp.
• Motor start switch/commutator (B) located on the left-hand side (near the lamp).
•
levers :
- lamp carriage traverse lever (L)
- Right-hand clamp lever (R) for rounding off cuts (bit and double bit)
3.4 Environmental conditions
To ensure that the best use is made of the key-cutting machine, certain parameters must be borne in mind:
• damp, badly ventilated sites should be avoided .
•
the ideal conditions for the machine are :
- temperature: between +10 and +40˚C
-
relative humidity: approx 60%
3.5 Graphics
Fig. 8
20 cm
20 cm
20 cm
100 cm
THE USE OF PROTECTIVE
GOGGLES IS COMPULSORY
(OFF)
(speed 1) (speed 2)
MOTOR START-UP COMMUTATOR
2 SPEED

Operating manual - English Technica
10 Copyright Silca 2005
4 REGULATION AND USE OF THE MACHINE
To get the most out of your key-cutting machine, check gauging periodically.
4.1 Micrometric tracer point
The choice of using a micrometric tracer point on a machine for cutting bit and pump keys allows perfect rapid
reading, as well as prompt resolution of the tiny variations in depth presented by worn keys.
Note: when the 2 ring nuts are turned together, each notch moves them 0.05 mm (with (D1) knob released)
4.2 Tracer point spring
The spring movement facilitates the identification of the cutting space before the cut is made.
• To activate the tracer point spring:
release the tracer point spring locking knob (D1) (fig. 9).
• To disable the tracer point spring:
push the tracer point up against its stop and secure with the knob (D1).
Fig. 9
4.3 Right-hand clamp movement
Fig. 10
[A]
Clamp aligned for gauging and key-cutting operations for pump keys and keys with centre stop.
Use the lever (S) to lock the right-hand clamp in a horizontal position.
[B]
Rocker clamp for cutting bit/double bit keys (rounding off cuts).
Release the right-hand clamp by lowering the lever (S).
D1
AB
SS

Technica Operating manual - English
Copyright Silca 2005 11
4.4 Checking and gauging
There are two types of regulation for the TECHNICA key-cutting machine, defined as axial gauging and depth
gauging
.
Fig. 11
4.4.1 AXIAL GAUGING ON BIT/DOUBLE BIT KEYS
Axial gauging is regulation of the spaces for the cuts on the key (fig. 11).
Checking axial gauging:
1) Turn the machine off and unplug it .
2) Use the lever (S) to lock the right-hand clamp in a horizontal position.
3) Use the handles (P) and (P1) to close the clamps.
4) Lock the tracer point spring.
5) Use the lever (L) to raise the carriage and take the stops (Y) for double bit keys up against the right-hand side
of the tracer point and cutter (fig. 12 and fig. 13).
The ideal situation is when the internal part of the left-hand stop is up against the right-hand side of the tracer point
and the internal part of the right-hand stop is in contact with the right-hand side of the cutter.
If this is not so, loosen the screw (D2) and use a screwdriver to regulate the screw (D4) (fig. 14, page 12) until the
ideal situation is reached.
Fig. 12
Fig. 13
cutting spaces
cutting
depths
S
PL
D2
P1
Y Y

Operating manual - English Technica
12 Copyright Silca 2005
Fig. 14
4.4.2 DEPTH GAUGING
Depth calibration is regulation of the cutting depth (fig. 11, page 11).
Depth gauging should be checked periodically to ensure perfect efficiency for the machine, and whenever the
cutter or tracer point is replaced (due to wear or job changeover)
.
CHECKING DEPTH GAUGING :
1) Turn the machine off and unplug it .
2) Use the lever (S) to lock the right-hand clamp in a horizontal position.
3) Place the adjusting pins (provided) on the clamps (fig. 15).
4) Disable the tracer point spring (chap. 4.2, page 10).
5) Release knob (D5) placed on ring nut (N).
6) Raise the carriage and take the setting pins into contact with the tracer point and cutting tool (fig. 15).
7) Turn the cutting tool anticlockwise manually and check that it skims the adjusting pins in several places.
8) If necessary, regulate the cutting depth by means of the tracer point, as described below:
c) turn the nut (N) clockwise to advance the tracer point (cut less deep).
d) turn the nut (N) anticlockwise to move the tracer point back (cut more deep).
9) Repeat these operations until the cutting tool skims the setting pins in several points.
10)Once obtained the corret gauging, lock ring nut (N) by tightening knob (D5).
11)After having locked ring nut (N) turn the other ring nut (N1) until the red indicator is aligned with the notch on
the tracer point.
Note: when the 2 ring nuts are turned together, each notch moves them 0.05 mm.
Fig. 15
D4
S
D1
N
N1
D5

Technica Operating manual - English
Copyright Silca 2005 13
4.5 Cutting operations
ATTENTION: to work in complete safety, pay special attention to the following recommendations:
• start the motor only when all the operations with the carriage have been carried out (securing keys,
etc
.)
• always work with dry hands.
• check that the machine is properly earthed.
• use the protective goggles, even if the cutting tool is fitted with a protective shield.
• keep the hands away from the cutting tool when in motion.
4.6 Cutting bit and double bit keys
1) Use the lever (S) to lock the right-hand clamp in a horizontal position.
2) Place the keys into the jaws, pushing them to the right until the bit is in contact with the key stop (Y). Close the
jaws, taking care that the keys are securely fitted into their seating and that the bits of the two keys are parallel.
3) Release the right-hand clamp by lowering the lever (S).
4) Switch the motor commutator to the correct position (1 = low speed for steel keys, 2 = high speed for brass
keys); turn the machine on and use lever (L) to take the carriage slowly towards the cutter, at the same time
raising lever (R) very slightly. With the clamp positioned lower than the cutter, starting from the right, cut the
key, lowering lever (R) to round off the cut. The spring incorporated in the carriage helps the operator by
returning the rocking clamp to its original cutting condition.
5) Cut the whole bit and remove any burrs at the end of the cutting operation.
6) For double bit keys, turn both keys and repeat the operations described above.
7) When the cutting operation is complete, turn the switch to “0” and remove the keys.
Fig. 16
LS
R
YY

Operating manual - English Technica
14 Copyright Silca 2005
4.6.1 CUTTING SHORT KEYS
If it is necessary to cut very short keys which do not come into contact with the key stop (Y) proceed as follows,
observing illustration 17.
1) Use the lever (S) to lock the right-hand clamp in a horizontal position.
2) Lock the keyblank into the right-hand jaw (M1).
3) Raise the carriage and rest the bit against the cutter; lock the carriage in position by tightening knob (G) (fig.
5, page 5).
4) Lock the original key into the left-hand jaw (M) resting the bit against the tracer point; in this way both keys will
be perfectly aligned.
5) Release the right-hand clamp by lowering the lever (S).
6) Loosen the knob (G) and carry out the cutting operation with a light touch, bearing in mind that the key tip has
no support.
Fig. 17
4.6.2 CUTTING DOUBLE FEMALE BIT KEYS
We can also use the instructions for cutting very short bit or double bit keys to cut bit or double bit (female) keys,
taking care to observe and check some dimensional and operational characteristics:
Dimensional:
Maximum height of bit against stem axis = 15 mm (max)
Maximum length of bit to be cut = 17 mm (max)
Operational:
• Between the end of the bit (towards the key head) and the left-hand internal side of the clamp there must be a
space of 2 mm (max) and no less than 1,5 mm (cutter thickness).
• During cutting (especially for iron keys) do not exert too much pressure when pushing the key towards the cutter,
as the key tip has nothing to butt against.
Note: the precision of keys cut in this way will refer to the external stem diameter rather than the centre of the
internal hole in the tip. Any imprecision between the hole axis and the stem is additional to the normal tolerance
for manual cutting.
Fig. 18
M1M
YY
15 mm (max.)
17 mm (max.)
2 mm (max.)
1,5 mm (min.)

Technica Operating manual - English
Copyright Silca 2005 15
4.7 Cutting keys with centre stop
Note: check that the right-hand clamp is locked in a fixed position.
1) Loosen the clamp handles slightly in order to position the keys.
2) Place the original key in the left-hand clamp with the centre stop up against the clamp (l/h side) and the bit
parallel to the clamp; tighten the handle (P) to secure the key.
3) Place the key blank in the right-hand clamp with the centre stop up against the clamp (l/h side) and the bit
parallel to the clamp; tighten the handle (P1) to secure the key.
Proceed with cutting:
1) Set the required cutting speed with the switch (B) and proceed with cutting.
2) Use the lever (L) to raise the carriage and take the original key into contact with the tracer point, pushing it all
the way in to complete cutting.
3) Use the lever (L) to pull the carriage back and go to another cutting position, then continue as in point 2 above.
4) When the cutting operation is complete, turn the switch to “0” and remove the keys.
Fig. 19
P

Operating manual - English Technica
16 Copyright Silca 2005
4.8 Cutting pump keys
1) Use the lever (S) to lock the right-hand clamp in a horizontal position (fig. 10, page 10).
2) Place the original key into the left-hand clamp (M) so that the bit rests against the lower jaw of the clamp (fig.
20).
3) Use the special groove for pump keys: for keys with round shafts and for keys with square shafts, such as
Mottura (fig. 21).
4) Place the keyblank into the right-hand clamp (M1) in the same way.
5) Set the required cutting speed with the switch (B) and proceed with cutting, raising the carriage and pushing
the tracer point all the way in for each cutting position.
6) Check the bit edges and rectify, if necessary.
7) When the cutting operation is complete, turn the switch to “0” and remove the keys.
Fig. 20
Fig. 21
Fig. 22
M M1