Silca Quattrocode User manual

®
Operating manual
D415175XA
vers. 3.0

(c) 1999 SILCA S.p.A. - Vittorio Veneto
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 SILCA S.p.A.
Second edition march 1999
Printed in Vittorio Veneto
by SILCA S.p.A.
Via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV)
Italy.
(*) IBM is a registered trade mark of the International Business Machine Corporation.
(**) Waste is defined as any substance or object deriving from human activity or natural cycles which has been thrown
away or will inevitably be thrown away.

QUATTROCODE Operating manual - English
Copyright Silca 1999 3
INDEX
CONSULTING THE MANUAL ........................................................................................ 5
GENERAL ....................................................................................................................... 6
PROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR ...................... 7
1 GENERAL DESCRIPTION .........................................................................................8
1.1 Main operating features ...................................................................................8
1.2 Safety devices .................................................................................................9
1.3 Technical data ...............................................................................................11
2 TRANSPORT ............................................................................................................12
2.1 Packing ..........................................................................................................12
2.2 Unpacking ......................................................................................................13
2.3 Handling the machine ....................................................................................13
3 INSTALLATION AND SETTING UP ........................................................................14
3.1 Checking for damage .....................................................................................14
3.2 Positioning .....................................................................................................14
3.3 Graphics ........................................................................................................15
3.4 Installation of the Silca Quattrocode Program software .................................15
3.5 Starting the Silca Quattrocode Program ........................................................15
4 MACHINE REGULATION .........................................................................................16
4.1 Machine keypad and functions of keys ..........................................................16
4.2 Decoder pocket ..............................................................................................17
4.3 Cutting tool replacement ................................................................................18
4.4 Use of the clamp ............................................................................................19
4.5 Fitting the clamp to the machine ....................................................................20
4.6 Turning the mobile jaw (P1) on clamp ‘J1’ .....................................................20
4.7 Key stop .........................................................................................................21
4.8 Anti-tilting device ............................................................................................22
4.9 Clamp detection .............................................................................................23
4.10 Clamp calibration ...........................................................................................23
5 DECODING KEYS ....................................................................................................25
5.1 Decoding ........................................................................................................25
6 KEY CUTTING ..........................................................................................................26
6.1 Data storage in the machine memory ............................................................26
6.2 Code selection ...............................................................................................26
7 TEST FUNCTIONS ...................................................................................................27
7.1 Sensor test .....................................................................................................27
7.2 Photocell test .................................................................................................30
7.3 Motor tests .....................................................................................................31
7.4 Display and keypad test .................................................................................33

Operating manual - English QUATTROCODE
4 Copyright Silca 1999
8 CLEANING ...............................................................................................................34
9 MAINTENANCE ........................................................................................................35
9.1 Trouble shooting ............................................................................................35
9.2 Maintenance operations ................................................................................36
9.3 Belt replacement and tension ........................................................................36
9.4 Checking and replacing the fuses ..................................................................37
9.5 Replacing the UNIPOW 50 Supply circuit board ...........................................40
9.6 Replacing the 1st ST2DRV module - X and Y axes step motors ...................41
9.7 Replacing the 2nd ST2DRV module - Z and A axes step motors ..................42
9.8 Replacing the 3rd ST2DRV module - B axis step motor ................................43
9.9 Replacing the CPU module ...........................................................................44
9.10 Replacing the inlet/outlet modules and terminal panel ..................................45
9.11 Replacing the keypad/display ........................................................................46
9.12 Replacing the electronic rack .........................................................................47
9.13 Access to the motor compartment .................................................................49
9.14 Access to the electrical parts in the base ......................................................50
10 DECOMMISSIONING ...............................................................................................51
11 AFTER-SALES SERVICE ........................................................................................52
11.1 How to apply for assistance ...........................................................................52

QUATTROCODE Operating manual - English
Copyright Silca 1999 5
CONSULTING THE MANUAL
This manual has been produced to serve as a guide for users of an electronic key-cutting machine
The contents of the manual are divided into sections relating to:
chapter
• Machine description ................................................................................................................ 1
• Transport and installation..................................................................................................... 2-3
• Regulation and use ...........................................................................................................4-5-6
• Tests and maintenance.....................................................................................................7-8-9
Technical terms
Common technical terms are used in this manual. To assist those with little experience of cutting
keys, below is an illustration of the terms most frequently used.
Fig. 1
1) Head
2) Neck
3) Shoulder
4) Stem
5) Tip
1
2
3
4
5

Operating manual - English QUATTROCODE
6 Copyright Silca 1999
GENERAL
QUATTROCODE has been designed according to the principles of the Machine Directives. From
the design stage risks for the operator have been eliminated in all areas: transport, regulation,
cutting and maintenance.
The material used in the manufacture of this machine and the components employed during use
are not dangerous and assure that Quattrocode complies with the Machine Directives.
Use
Quattrocode has been designed for the copying of keys. It must be installed and used in the way
laid down by the manufacturer. If the 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 S.p.A.
Furthermore, unforeseen danger to the operator or any third parties may arise from incorrect use
of the machine.
Improper use
Negligence in the use of the machine or 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 key-cutting machine and benefit from its potential.
Further risks
WARNING: during cutting operations
there is a risk of hands being
crushed. To avoid this, keep
hands well away from the area
circled in the drawing.

QUATTROCODE Operating manual - English
Copyright Silca 1999 7
PROTECTION AND SAFETY PRECAUTIONS FOR THE OPERATOR
The Quattrocode fully complies with the Machine Directives. The operations for which it has been
designed are easily carried out at no risk to the operator.
The adoption of general safety precautions and observation of the instructions provided by the
manufacturer in this manual eliminate all human error, unless deliberate.
The Quattrocode is designed with features which make it completely safe in all its parts.
Characteristics
•Power supply
Quattrocode must be provided with electricity having the same voltage as that shown on the rating
plate, supplied through an earthed socket and differential switch.
•Start-up
The machine is started up by means of a master switch placed on the back.
•Maintenance
The operations to regulate, service, repair and clean the machine have been devised in the
simplest and safest way possible. There is no danger of removable parts being replaced wrongly
or unsafely.
•Machine identification
The machine is provided with an identification label which shows the serial number (fig. 2).
Fig. 2
(*) see Ch. 10 "DECOMMISSIONING", page 51.

Operating manual - English QUATTROCODE
8 Copyright Silca 1999
1 GENERAL DESCRIPTION
Quattrocode is an electronic machine operating on three controlled axes. Meticulously designed
down to the finest details, it combines operating speed with ease of use and high precision results.
The machine operates linked to a personal computer. The operating programs are set up with the
machine keypad.
Fig. 3
1.1 Main operating features
•Movements
Movement of the three axes (x-y-z) operates with pre-loaded ball screws, driven by step motors on
ground roller guides.
•J1 clamp
Standard clamp designed to house almost all dimple or laser keys.
•Cutting shaft
Comprises an electrically controlled tool-locking system.
•Cutting tool
An easily replaced cutting tool (HSS or hard metal) with resistance and cutting properties suitable
for the type of work and speed of rotation.
•Display
Alphanumeric display with scrolling text on 2 lines of 12 characters each, placed on top of the
machine.
Its design and position ensure practical, easy use.

QUATTROCODE Operating manual - English
Copyright Silca 1999 9
1.2 Safety devices
The transparent protective shield is designed to cover and render as safe as possible the working
parts of the machine.
The shield (D) must be raised to fit keys for cutting or carry out any other operations on the
machine. Raising of the shield is controlled by a microswitch (D1) (fig. 5, page 10) and disactivates
the working and movement functions, including the cutting tool. The fact that the shield is not down
is indicated by a message on the machine display.
To re-activate the work cycle, place the shield in its initial position and press the START button on
the machine keypad.
Fig. 4
•Emergency stop
The machine can be cut off by means of the red emergency button (A) placed on the left. When this
button is pressed the machine stops immediately when there is a serious malfunction or risk of
danger for the operator. After elimination of the cause of the emergency, turn the button 45°
clockwise.
N.B.: it is the operator’s responsibility to keep clear the area around the emergency button
so that it can be reached rapidly.
D
A

Operating manual - English QUATTROCODE
10 Copyright Silca 1999
Main working parts
Fig. 5
A emergency button
B clamp detector sensor
C spindle
D mobile protective shield
D1 safety microswitch
E decoder holder
F display
F1 keypad
G electronic rack
H Z axis carriage
I halogen lamp
J tool
K start switch
L 2nd IN-OUT serial port (various)
L3 1st serial port (computer)
M switch socket (for future use)
M2 special clamp connector
N X axis connector
O2 X axis carriage
P knob
P1 rotating jaw
Q Y axis carriage
R J1 basic clamp
S metal chip tray
T Z axis setting plate
U101 LASER key decoder
U102 Dimple key decoder
P1
Q
R
S
O2P
T
I
F1
D
F
B
H
C
J
D1
E U101 U102
A
L3
M2N
G
L
K
M

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Copyright Silca 1999 11
1.3 Technical data
POWER SUPPLY: Single phase 220V (110V - 60 Hz)
MAX. ABSORBED POWER: 1.5 Amp (350 W) (110V: 3 Amp (350W)(
CUTTER MOTOR: Two-speed single phase
CUTTING TOOLS: in HSS (high speed steel) or Widia (hard metal)
CUTTER SPEED: 6000 rpm (+/- 10%) (HSS) / 12000 rpm (+/- 10%) W
(hard metal)
MOVEMENTS: On three axes with preloaded recirculating ball screws
activated by step motors on ground roller guides.
Cutting tool spindle released and locked by a step motor.
CLAMP: Universal ‘J1’ (standard) for key lock grip, reversible
mobile jaw for locking special ‘Z’ profile Mercedes keys.
RUNS: X axis: 55 mm
Y axis: 55 mm
Z axis: 55 mm
DIMENSIONS: Width 390 mm / depth 530 mm / height 570 mm
MASS: 60 kg.
NOISE RATING: Noise pressure: Lp (A) = 79.16 dB (A)
Personal Computer
The personal computer (not included) to be used for transmission of the operating program to the
Quattrocode should have the following minimum specifications:
- Model: IBM1 or 100% IBM compatible - Microprocessor 80286 at 12 Mhz or over.
- Operating system: MS-DOS version 3.30 or later
- RAM: minimum 640 Kb
- Floppy disk unit: 1 x 1.2 Mega (5
- Minimum hard disk capacity: 5 MB
- Serial port: RS-232
- Parallel port (printer): Standard
- Video screen: VGA Monochrome
A Pentium 90Mhz microprocessor is preferable
- Version MS-DOS 6.0
- Video VGA-Colour (High Resolution Graphics)
N.B.: proper operation of the program and data transmission from the personal computer to
the Quattrocode key-cutting machine cannot be guaranteed unless the personal computer
‘BIOS’ is 100% IBM compatible.
Accessories provided
Quattrocode is provided with a set of accessories for use and maintenance of the machine (tools,
hex. wrenches, fuses, etc.), found in the tool box provided.
Tool box Locking bar Screwdriver handle
13 mm wrench Gauging template and pin 2 mm socket head
10 mm wrench A - 4 Amp. fuse - rapid 2.5 mm socket head
7-8 mm wrench B - 1 Amp. fuse - delayed 3 mm socket head
1.5 mm allen wrench C - D - E - 4 Amp. fuse- delayed 4 mm socket head
5 mm allen wrench F - 1.6 Amp. fuse - delayed Flat screwdriver
6 mm allen wrench G - 3.15 Amp. fuse - rapid Star screwdriver
Elbowed wrench 3 m serial cable 25/9 pin
Straight brush Jumper cable

Operating manual - English QUATTROCODE
12 Copyright Silca 1999
2 TRANSPORT
The key-cutting machines are easy to transport and not dangerous to handle.
The packed machine can be handled manually by two people.
2.1 Packing
The packing for the Quattrocode guarantees sure and safe transport for the machine and all its
component parts. It comprises a pallet base (b), to which the machine is anchored, and a
cardboard cover (a).
Fig. 6
The machine is attached to the base by means of screw-down brackets which hold it in place during
transport, avoiding damage, especially to the protective shield.
The sealed cardboard cover is attached to the pallet by means of two straps which hold it securely
in place.
Symbols on the cardboard cover show the ideal conditions for transport.
To avoid knocks which could damage the Quattrocode, we recommend using the original
packing every time the machine is transported, securing it to the base with the special
brackets.
a
b
Keep dry This side up Use no hooks
Handle
with care

QUATTROCODE Operating manual - English
Copyright Silca 1999 13
2.2 Unpacking
To remove the machine from the packing:
1) cut the straps with scissors and remove them.
2) raise the top of the cardboard cover.
3) unscrew the 3 screws (c) securing the front bracket to the pallet (fig. 7).
4) unscrew the 3 screws (c) securing the rear bracket to the pallet (fig. 7).
5) use the wrench provided to loosen the nuts on the rear feet by a couple of turns.
6) remove the metal brackets (fig. 7).
7) check that the packing box contains:
- 1 Quattrocode key-cutting machine
- 1 set o documents, including: Operating Manual, QUATTROCODE PROGRAM manual,
spare parts list and guarantee
- 1 power supply cable
- 1 tool box
8) keep the packing to use every time the machine is transported.
Fig. 7
2.3 Handling the machine
When the Quattrocode has been unpacked, place it directly on its workbench.
This should be done by two people, holding the metal base firmly to lift the machine.
cc

Operating manual - English QUATTROCODE
14 Copyright Silca 1999
3 INSTALLATION AND SETTING UP
Installation can be carried out by the purchaser and does not require any special skills.
The key-cutting machine is supplied ready for use and assembly is not necessary. However, some
checks and preparation for use need to be carried out.
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 0 and 40°C, relative humidity approx. 60%.
3.1 Checking for damage
The Quattrocode is solid and will not normally damage if transport, unpacking and installation have
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
• Place the machine on a horizontal surface, solid enough to take the weight (60 kg). The
workbench should ideally be at a height of approx. 100 cm, which ensures easy access to the
working parts. Leave at least 30 cm clearance behind the machine to provide ventilation and
30 cm on both sides.
• Connect the power supply cable and the serial cable to their sockets.
WARNING: 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. 8
Switch
Rear view
30 cm.
30 cm.
30 cm.
100 cm.
30 cm.

QUATTROCODE Operating manual - English
Copyright Silca 1999 15
The machine needs only one operator, who has the following controls at his/her disposal (fig. 5,
page 10):
- motor start switch (K), placed on the back of the key-cutting machine;
- key positioning clamp (R);
- control keypad (F1);
- emergency button (A).
3.3 Graphics
Two adhesive warning and instructions labels are attached to the plexiglass shield (fig. 9). These
must not be removed.
Fig. 9
3.4 Installation of the Silca Quattrocode Program software
- Connect the personal computer and QUATTROCODE with the serial cable provided. Make
the connection between the personal computer serial port and the connector (L3) on the
Quattrocode (fig. 10).
- Turn on the Quattrocode and the computer.
- Install the QUATTROCODE PROGRAM software on the PC. To do so consult the manual
provided with the software package for the installation and use of the "SILCA
QUATTROCODE PROGRAM".
- Ensure that the U101 - U102 decoders are housed in the special decoder pocket on the left-
hand side of the machine.
Fig. 10
3.5 Starting the Silca Quattrocode Program
When the SILCA QUATTROCODE PROGRAM has been installed on your PC, to work with the
program enter the following command:
<QCODE> + ENTER
The SILCA logo will appear, followed by the main menu.
Danger to eyes! Do not use compressed air
for cleaning
L3

Operating manual - English QUATTROCODE
16 Copyright Silca 1999
4 MACHINE REGULATION
4.1 Machine keypad and functions of keys
Fig. 11
The keypad incorporated in the Quattrocode, illustrated in fig. 11, enables the operator to use the
machine rapidly and easily once the work program has been transmitted by the PC.
Only the keys necessary for the cycle in progress (except the STOP button, which is always active)
are constantly enabled, e.g. when the cutting tool is being changed only the keys for releasing and
locking the spindle and the START button are active; all the other keys are excluded, even if
pressed.
striking this key starts the machine TEST function (indicated by the illumination of the red
led in the corner of the key).
keys reserved for future functions.
spindle release (active only when the tool change message is screened).
spindle lock (active only when the tool change message is screened).
enables forward scrolling on the display of the key queue transmitted by the PC.
enables backward scrolling on the display of the key queue transmitted by the PC.
- during the TEST moves the step motors in one direction
- during work operations starts scrolling of the writing on the display (if it comprises more
than the 12 characters shown)
- during the TEST moves the step motors in the other direction
- during work operations stops scrolling of the writing on the display.
a) starts the cutting operation (by code) on the key selected from those on the
display.
b) re-starts the cutting operation after interruption to change the cutting tool or turn
the key.
c) starts the cutting tool TEST function.
Acts as function key to enable an operation transmitted by the PC or the machine
The START button has a green led which illuminates to indicate work in progress.
stops the operation in progress at any given moment, returning the axes to the idle
position.
switches the lamp on or off.
TEST
F6 F8F7F5
START
STOP

QUATTROCODE Operating manual - English
Copyright Silca 1999 17
4.2 Decoder pocket
A special device (E) is installed on the left-hand side of the machine to house the decoders when
they are not in use (fig. 12).
Fig. 12
The decoders provided are:
Fig. 13
The device is designed to house a third decoder (U103 - not provided), whose place is
occupied by an imitation decoder (U) which should never be removed.
The decoders must be replaced in the device after use.
Before starting to cut a key, the machine checks that all the housings are occupied. If not, the
machine stops and shows the following message on the display:
<DECODER WRONGLY
POSITIONED>
WARNING: this safety system ensures that the cutting tool is not used instead of the decoder, or vice
versa.
E
U102
U101
U
U101
decoder for setting the
clamp and decoding
LASER type keys
U102
decoder for decoding
dimple keys

Operating manual - English QUATTROCODE
18 Copyright Silca 1999
4.3 Cutting tool replacement
The cutting tool can be fitted or replaced only at one point in the work process, when the display
shows, i.g.:
<INSTALL CUTTING TOOL H101>
WARNING: to describe cutting tool replacement, tool 101 is used as an example. For the other cutting
tools, carry out the same sequence with the tool required.
To remove a decoder or cutting tool from the spindle, proceed as follows:
- Raise the protective shield (D);
- with one hand hold the cutting tool or decoder to be removed;
Press the spindle release key with the other hand;
- remove the cutting tool. The decoder must be replaced in its housing on the decoder pocket
(E) on the machine (fig. 12, page 17), whereas the cutting tool must be placed in its housing
on the tool board provided.
To install a cutting tool, proceed as follows:
- Raise the protective shield (D);
release the spindle, if necessary, by pressing the spindle release key;
- fit the cutting tool into the spindle, pushing all the way in;
hold the cutting tool in place with one hand and with the other press the spindle locking
key.
Fig. 14
WARNING: when an operation is begun by pressing START (cutting), the situations described below
may occur:
1) Spindle locked with tool missing:
the machine seeks the setting for the Z axis by moving the spindle over the special plate
on the clamp. As this causes the spindle to come into close proximity (over the safety
measurement) to the plate, the cycle in progress is stopped, the spindle is moved back to
its initial position and the display shows the message:
<INSTALL H101>
2) Spindle released (tool missing)
the machine fails to start the cutting cycle. The display shows the same message:
<INSTALL H101>
WARNING: the type of cutting tool to install may be identified by the letter H (HSS) or W (hard metal).
This means that the QUATTROCODE will automatically use cutting speed 1 (HSS) or 2 (W - hard
metal) (see Ch. ‘Accessories’ in the SILCA QUATTROCODE PROGRAM manual).

QUATTROCODE Operating manual - English
Copyright Silca 1999 19
4.4 Use of the clamp
The machine is supplied with the ‘J1’ standard clamp illustrated in fig. 15.
Fig. 15
As shown in fig. 15, the ‘J1’ clamp has a fixed plate (R1) on top and a mobile jaw (P1), both of
which can be replaced when worn.
The clamp also has a setting plate (T) for the Z axis (sprung), over which the cutting tool zeroes
before starting cutting operations on a new key. The plate is sprung to avoid microfractures when
the cutting tool makes contact with it.
WARNING: to ensure that the Z axis works accurately, keep the setting plate (T) perfectly clean by
brushing any metal chips off regularly, using the brush provided.
WARNING: do not exert excessive pressure to lock the key in the jaws. Turning the knob
approximately 70˚ (clockwise) when the jaws start to grip the key is sufficient (fig. 16). It is
also important to ensure that the key lies absolutely flat in the jaw during locking so that
it cannot bend, twist or rest unevenly on the plate (fig. 16).
Fig. 16
R1
P1
T

Operating manual - English QUATTROCODE
20 Copyright Silca 1999
4.5 Fitting the clamp to the machine
Fit the clamp into the carriage dovetail, push all the way in and lock by means of the knob (P2) (fig.
17).
Although Quattrocode is designed to take up to 16 different clamps (identified progressively from
"J1" to "J16") the instructions refer only to the clamp provided (J1). The other clamps are all
provided with their own instructions.
4.6 Turning the mobile jaw (P1) on clamp ‘J1’
Clamp "J1" is supplied with mobile jaws (P1) which can be reversed (sides A and B) to facilitate
locking (on side B) of special profile Mercedes keys (corresponding to Silca articles HU41P,
HU41AP, HU44AP, HU55P, HU61AP) without the need for additional adapters (fig. 17).
When side B is in use the display shows a message.
Fig. 17
To take the jaw (P1) into position B, proceed as described below:
1) move the jaw upwards then to the left (fig. 18-A);
2) from this position, turn the jaw 90° to the left (fig. 18-B);
3) raise the jaw as shown in fig. 18-C and turn 90° to the left (fig. 18-D);
4) move the jaw to the right fig. 18-E).
To take the jaw to its initial position (fig. 17), carry out the same process in reverse order.
Fig. 18
A
B
P
P1
P2
AB
CDE