Silca REKORD User manual

Operating manual
®
D433453XA vers. 4.0

© 2007 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 2009
Printed in Vittorio Veneto
by SILCA S.p.A.
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy
IMPORTANT NOTE: in compliance with currentregulations relating to industrial property, we hereby state that the
trade-marks or trade names mentioned in our documentation are the exclusive property of authorized
manufacturers of locks and users.
Said trade-marks or trade names are nominated only for the purposes of information so that any lock for which our
keys are made can be rapidly identified.

INDEX
1 TRASPORT .....................................................................................................5
1.1 Packing .................................................................................................5
1.2 Transport . .............................................................................................5
1.3 Unpacking .............................................................................................5
1.4 Handling the machine ...........................................................................5
2 WORKING PART ............................................................................................6
3 MACHINE DESCRIPTION ...............................................................................7
3.1 Technical Data ......................................................................................8
3.2 Electric circuit .......................................................................................9
4 ACCESSORIES PROVIDED .........................................................................10
5 MACHINE INSTALLATION and PREPARATION ........................................11
5.1 Checking for damage .........................................................................11
5.2 Environmental conditions ...................................................................11
5.3 Positioning .. ........................................................................................11
5.4 Removing the blocks ..........................................................................12
5.5 Separate parts ....................................................................................12
5.6 Connection to the mains .....................................................................12
5.7 Description of work station .................................................................13
5.8 Graphics .. ...........................................................................................13
6 MACHINE REGULATION AND UTILIZATION .............................................14
6.1 Checking and setting ..........................................................................14
6.2 Calibration .. ........................................................................................14
7 KEY CUTTING ...............................................................................................16
7.1 Key cutting ..........................................................................................16
8 MAINTENANCE ............................................................................................20
8.1 Replacing the cutting tool ...................................................................20
8.2 Replacing the brush ............................................................................21
8.3 Replacing and/or tightening the belt ...................................................21
8.4 Replacing the tracer point ...................................................................22
8.5 Regulating carriage depth ..................................................................23
8.6 Replacing the fuses ............................................................................23
8.7 Access to the lower part ......................................................................24
8.8 Replacing main switch.........................................................................24
8.9 Replacing motor/condenser.................................................................25
8.10 Replacing lamp feed (transformer) .....................................................26
8.11 Replacing lamp set/lamp protection ....................................................26
8.12 Replacing motor start switch ...............................................................27
9 DISPOSING OF MACHINE............................................................................28
10 ASSISTANCE ................................................................................................29
10.1 How to request service .......................................................................29

Operating manual - English REKORD
Copyright Silca 2 007 3
GUIDE TO THE MANUAL
This manual has been produced to serve a s a guide for users of the REKORD key-cutting machin e.
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 ................................................................................................... Ch.1
- Description of machine and safety devices .................................................................... Ch.2-3-4-5
- Proper use of machine .................................................................................................... Ch.6-7
- Maintenance .................................................................................................................... Ch.8
Technical terms
Common technical terms are used in this manual. To assist those with little experience of key cutting,
below is an illustration of the terms used for the different parts of keys:
Fig. 1
1) Head
2) Rim
3) Stop
4) Stem
5) Tip
6) Back
7) Cuts
8) Stem
1111
3
3
3
3
7
7
8
2
2
2
5
55
5
4
4
6
6
only for
SOFERversion only for BRAZIL version
1
8
3
5

REKORD Operating manual - English
4 Copyright Silca 2 007
GENERAL INTRODUCTIONS
The REKORD key-cutting machine has been designed according to the specifications of the Machine
Directives. From the design stage risks for the operator have been eliminated in all areas: transport, key-
cutting, regulation and maintenance.
Other risks have been eliminated by the use of protective devices for the operator.
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 th e machine warning the operator to use goggles during the
cutting operations, and this is strongly recommended in this manual.
The material used in the manufacture of this machine and the components employed during use of the
machine are not dangerous and their use complies with standards.
Use
The REKORD must be installed and used in the way laid down by the manufacturer.
If th e key-cuttin g ma chine is used differently or for purposes differ ent from those describe d 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.
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 REKORD 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
There are no further risks arising from the use of the machine.
Protection and safety precautions for the operator
The REKORD key-cutting machine is built entirely to standards. The operations for which it has been
designed are easily carried out at no risk to the operator.
The a doption o f g eneral safety precautions (wearing pro tective gog gles) an d observatio n of the
instructions provided by the manufacturer in this manual eliminate all human error, unless deliberate.
The REKORD key-cutting mach ine is designed with features which make it completely safe in all its
parts.
•Power supply
The key-cutting machine is powered by electricity supplied through a separable earthed plug.
•Start-up
The machine is started up:
- Activating the safety main switch on the right-hand side of the machine.
- Activating the motor on switch the left-hand side.
• Maintenance
The operations to regulate, service, repair and clean the mach
ine have been devised in the simplest and
safest way possible. There is no danger of removable parts being re-placed wrongly or unsafely.
• Machine Identification
The REKOR D key-cutting machine is provi ded w ith an iden tification la bel w hich show s the seria l
number (fig. 2).
Fig. 2
(*) see chap. 9 "DISPOSING OF MACHINE", page 28.

Operating manual - English REKORD
Copyright Silca 2 007 5
1 TRANSPORT
The REKOR D key-cutting machin e is easily transpor ted an d is not da ngerous to ha ndle. Th e packed
machine can be carried by one person.
1.1 Packing
The REKORD is packed in a strong cardboard box, the dimensions of which are shown in fig. 3, sufficiently
robust to be used for storing the machine for long periods.
Inside the box the machine is enclosed in two expanded polymer shells. The shells and cardboard box
ensure safe transportation and protect the machine and all its parts.
Fig. 3
1.2 Transport
To avoid damaging th e R EKORD it must alw ays be tr ansported in its packin g case. This will prevent
sudden movements or rough handling from damaging the machine, persons or things.
1.3 Unpacking
To remove the machine from the packing box:
1) cut the straps with scissors and remove.
2) prise off the staples.
3) open the box without damaging it as it may be used again (e.g. removals, dispatch to the manufacturers
for repairs or servicing).
4) check the contents of the box, which should comprise:
- 1 REKORD key-cutting machine packed in a protective shell.
- 1 set of documents, including: operating manual, spare parts list and guarantee.
- 1 connecting wire.
- 1 carriage lever handle;
- 1 tool kit.
5) remove the key-cutting machine from the protective shell.
1.4 Handling the machine
When the REKORD 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.
490
540
380
Keep dry This side up
Handle with care

REKORD Operating manual - English
6 Copyright Silca 2 007
2 WORKING PARTS
Fig. 4 A-carriage lever handle
B-carriage release lever
C-chippings tray
C1 - tool tray
D-carriage movement lever
E-clamps
F-clamp knobs
G - gauge knobs
H-gauge tabs
H1 - lamp
I - tracer point
J-tracer point locking grub screw
K - centesimal ring
L - cutting tool
M - top cover
N-
motor on switch
O - main switch
P-brush
Q - protective pad
R-clamp carriage
S - motor
U - fuses
V-supply socket
W - protective belt cover
B CA C1
D
E
G
F L M
O
P
R
S
H1
w
UV
I
J
K
N
H
Q

Operating manual - English REKORD
Copyright Silca 2 007 7
3 MACHINE DESCRIPTION
REKORD is a professional cutting machine for flat keys used with cylinder, car locks and cruciform keys.
The main parts of the machine are described below:
Main switch
The ke y-cutting machine is co nnected to a pow er supply so cket provided wit h a differentia l switch.
Pressing the switch (O) pow ers the machine a nd il luminates th e wa rning li ght (H1) to indicate that
current is on.
ATTENTION: Switch (O) is electromagnetic, in the event of a power failure it goes out
automatically. When electricity is restored it must be reset manually to power the machine again.
Motor on switch
The motor on switch (N) is placed on the left-hand side of the REKORD key-cutting machine.
ATTENTION: the illuminated switch remains on to indicate that the key-cutting machine has been started
(cutter in motion).
Motor and transmission unit
The motor has belt transmission. The transmission unit is placed on the left of the motor and activates
the brush (P) and cutting tool (L). These components are protected by two covers:
-protective belt cover (W),
-top cover (M).
Clamp carriage
The clamp carriage (R) consisting of two clamps, is fitted to the horizontal movement carriage, controlled
by lever (D) and is provided with a handle (A) under which can be found the carriage release button (B).
The carriage movement by means of gears, allows high precision movements which greatly facilitate all
cutting operations.
The carriage is fully protected by a special pan el designed to prevent the accumula tion of dust an d
chippings from the work process.
The machine is designed with a ramp along which chippings can fall into the special chippings tray (C),
placed under the carriage and easily removable for emptying and cleaning.
Cutting unit
The cutting unit contains the actual working parts of the REKORD key-cutting machine, which operate
together to cut and finish keys "read" from the originals.
The working parts are described below:
•Brush
The brush (P) is used to eliminate burrs from the cuts and is made of non-abrasive material.
•Cutting Tool
The cutting tool (L) is the part of the REKOR D used for cutting key blanks. The cutting tool is in H SS
super rapid steel and is protected by a special cover (M) to ensure safe operation.
•Tracer point
The tracer point (I), used for reading the profile of the key to be copied, is housed on the left-hand side
of the machine base. A centesimal ring (K) ensures regulation of the depth.
•Clamps
The clamps (E) have four sid es which rotate to allow the key to be perfectly secured on its back or in
profile (fig. 13-B).
•Clamp knobs
The clamps a re locked by two anatomical knobs (F) which ensure perfect grip on the keys with only
slight locking pressure.
•Calibration tabs
The clamps have two gauge tabs (H) with which to adjust key alignment.

REKORD Operating manual - English
8 Copyright Silca 2 007
3.1 Technical Data
ELECTRICAL PROPERTIES:
- 230V - 50/60Hz 370W 2A
- 120V - 60Hz 560W 4,6A
CUTTING TOOL: HSS Super Rapid Steel
MOTOR: One-speed single phase
- 230V - 50/60Hz; 1350/1620 rpm 0,18 Kw
- 120V-60Hz; 1620 rpm 0,18 Kw
MOVEMENTS: by gear on rectified carriage
CLAMP: rotating with four sides, high precision
MAXIMUM LENGTH OF CUTS: 43 mm (carriage run)
DIMENSIONS: width: 330mm (with max. lever encumbrance 510mm) depth: 430mm height: 270mm
SONOROUS PRESSURE: Leq. = 82.5 dB (brass keys)
SONOROUS PRESSURE: Leq. = 87.5 dB (iron keys)
Note: the equivalent sonorous pressure for the iron keys during the normal use (around 50 keys a day)
it is inferior to 85 dB.
WEIGHT: 19 kg.

Operating manual - English REKORD
Copyright Silca 2 007 9
3.2 Electric circuit
The REKORD key-cutting machine is provided with a single phase one-speed motor;
-1350 rpm, consumes approximately 0.18 Kw, absorption 2A (230V-50Hz)
-1620 rpm, consumes approximately 0.18 Kw, absorption 2A (230V-60Hz)
- 1620 rpm, consumes approximately 0.18 kw, absorption 4,6A (120V-60Hz)
The main parts of the electric circuit on the REKORD are listed below:
1)
Main plug with fuses
2) Safety main switch
3) Illuminated switch
4) Motor: 230V a.c. 50/60Hz - (120V a.c. 60Hz)
5) Condenser
6) Feeder
7) 6 LED circuit board (lamp)
black
red
Feeder (lamp)
6 LED circuit board
brown
light bluelight blue
brown
yellow/green
1
23
6
4
7
5
()
()
(lamp)

REKORD Operating manual - English
10 Copyright Silca 2 007
4 ACCESSORIES PROVIDED
To ensure trouble-free working with the REKORD, it is advisable to always have certain spare parts on
hand. It is advisable to always have a tool box containing: tools, cutting tools, brushes, belts and small
replacement parts.
REKORD is supplied with a full range of accessories.
The accessories provided by Si lca are all that is ne cessary to ca rry out the op erations for which the
machine is designed.
Fig. 5
C1
ADHESIVE LABEL
“DANGEROUS MOBILE PARTS”
STEEL PIN Ø 1,20
2 pcs
STEEL PIN Ø 1,70
2 pcs
STEEL BAR
2 pcs
5X20 FUSES (2 pcs)
4 Amps rapid (230V)
8 Amps rapid (120V)
2,5 mm ALLEN KEY
3 mm ALLEN KEY
19 mm SPANNER
10 mm SPANNER
CUTTING TOOL
UNCLAMPING PIN
ADJUSTING BAR
2 pcs
4 mm ALLEN KEY
5 mm ALLEN KEY
ATTENTION
DANGEROUS
MOBILE PARTS

Operating manual - English REKORD
Copyright Silca 2 007 11
5 MACHINE INSTALLATION AND PREPARATION
The REKORD key-cutting machine can be installed by the purchaser and does not require any special
skills.
However, some checks and preparation for use need to be carried out by the operator.
5.1 Checking for damage
The REKORD ke y-cutting ma chine is solid and compact an d w ill 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.
5.2 Environmental conditions
To ensure that the best use is made of the REKORD 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: from 0 to 40°C
- relative humidity: approx. 60%
5.3 Positioning
Place the key-cutting machine on a horizontal surface, solid enough to take the weight (19 Kg).
To facilitate operation and maintenance, install the machine with a space of at least 200 mm on all sides
(fig. 6).
Ensure that the machine stands pe rfectly bal anced on the four fee t. Vibration is avoided wh en th e
machine is properly set on the horizontal plane.
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. 6
200 mm
200 mm
200 mm

REKORD Operating manual - English
12 Copyright Silca 2 007
5.4 Removing the blocks
Remove the 2 blocks: on the carriage movement and between cutter and jaw (fig. 7).
Fig. 7
5.5 Separate parts
The separately pa cked pa rts must b e
installed on th e REKORD ke y-cutting
machine by the purchaser, as follows:
Connection wire
Connect the key-cutting machine p ower
cable to the electricity mains (fig. 8).
Fig. 8
Carriage lever handle
Screw the carriage handle as shown in fig. 9.
Fig. 9
5.6 Connection to the mains
For the safety of the operator and the machine it is important to ensure that the machine is connected
to the proper mains voltage by means of an earthed differential switch.
electricity
supply
power
cable

Operating manual - English REKORD
Copyright Silca 2 007 13
5.7 Description of work station
The key-cutting machine needs only one operator, who has the following controls at his/her disposal:
- Switch on the lamp by activating the main switch (O) located on the right-hand side of the machine.
- The motor on switch (N), located on the left-hand side of the machine has a warning light to show
that the key-cutting machine is live.
-Carriage movement lever (D)
-Carriage handle lever (A)
-Carriage release lever (B)
-Gauge knob (G).
Fig. 10 
5.8 Graphics
ABD
N
G
THE USE OF
PROTECTIVE GOGGLES
IS COMPULSORY
ATTENTION
DANGEROUS
MOBILE PARTS
Place the adhesive label “Dangerous
mobile parts” (ch .4, p age 10 ) as
shown.

REKORD Operating manual - English
14 Copyright Silca 2 007
6 MACHINE REGULATION AND UTILIZATION
6.1 Checking and setting
The cutting tool on the REKOR D is the part used to cut the ke y blanks and sho uld be period ically
checked and replaced, if necessary.
Every time the cutting tool is changed, and during periodical operational tests, check calibration.
6.2 Calibration
The REKORD key-cutting machine requires two types of calibration: axis and depth.
Axis calibration:
Axis calibration is regulation of the space between the stop and the cuts (fig. 11).
The axis setting for the REKORD is fixed and is established on assembly in our workshops
Fig. 11
Depth calibration:
Depth calibration is regulation of the cutting depth (fig. 11-A).
Proceed as follows:
1) Ensure that the key-cutting machine is off by unplugging the power cable.
2) Place the adjusting keys (provided) on the clamps (fig. 12-B).
3) Check that the adjusting keys adhere properly to the clamps (fig. 12-B).
4) Turn the gauge rod (G) towards the operator so that the gauges come into contact with the adjusting
keys (fig. 12-B). Lower the gauge rod (G).
5) Release the carriage by raising the release lever (B) (fig. 4).
6) Raise the carriage and take up to the cutting tool.
7) Take the keys into contact with the cutting tool and tracer point.
8) Turn the cutting tool anticlockwise manually and check that it skims the adjusting keys in several
places.
9) If necessary, regulate the depth of the cut with the micrometric tracer point, as follows:
a) loosen the screw holding the tracer point (J).
b) turn the grub screw (K) clockwise to advance the tracer point.
c) turn the grub screw (K) anticlockwise to return.
ATTENTION: each notch on the centesimal ring corresponds to 0,025 mm (fig. 12-A).
10) Repeat these operations until regulation is complete, then tighten the tracer point locking grub scre
(J).
64890
cutting
I II III IV V VI
cutting
space
depth
B
A

Operating manual - English REKORD
Copyright Silca 2 007 15
Fig. 12
0,025 mm
0,1 mm
AB
G
K

REKORD Operating manual - English
16 Copyright Silca 2 007
7KEY CUTTING
ATTENTION: 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 has a protective shield over the cutting tool.
- Start the motor (switch N) only after completing the operations on the carriage (securing the
keys, etc.).
- Keep hands away from the cutting tool in motion.
7.1 Key cutting
1) Turn the clamps to find the appropriate side for securing the key (fig. -B).
2) Loosen the knobs (F) by a couple of turns (fig. -A).
3) Raise the lower part of the clamps and turn to the required position:
- Side A of the clamp: for keys to be fitted on their backs (fig. -B)
- Side B of the clamp: for keys placed on their backs and having cuts with a depth of less than 3,9
mm (fig. -B))
- Side C and D of the clamp: for keys to be cut on both sides and locked on the groove (fig. -B)
Securing the keys in the jaws
1) Position the original key (left-hand jaw) and key blank (right-hand jaw), ensuring that:
a) the keys are positioned and secured in the clamp;
b) the key stop is resting against the calibration tabs (H);
2) secure the keys by closing the clamps with the knobs (F).
Fig. 13
D
A
B
C
F
HAB
A
SOFER Version
D
A
B
C
B
F
H

Operating manual - English REKORD
Copyright Silca 2 007 17
Key cutting
When the R EKORD key-cutting machine has been turned on by means of switch (O) it i s ready for
cutting:
1) Make sure the gauge rod (G) has been lowered.
2) Take the carriage up to the tracer point and cutting tool by releasing the push lever (B).
3) To copy the key, move the carriage sideways from right to left by means of the lever (D).
4) Turn off the machine with main witch (O) before removing the duplicated key.
5) Remove the keys from the clamps.
6) Turn on the machine with switch (O) and smooth off the key edges by means of the brush (P).
Fig. 14
D
A
B
C
F
HAB
BRAZIL version
key blank
original key

REKORD Operating manual - English
18 Copyright Silca 2 007
Using the accessories
The accessories provided with the REKORD to assist key-cutting are:
-pins
- bars.
Using the pins
The pins must be inserted between the bottom of the jaw and the back of the key for keys with narrow
stems, and their purpose is to ensure that the key protrudes sufficiently to be cut properly (fig. 15, fig.
15-C).
For keys with narrow, thin stems, two pins must be used (fi g. 15-B), the second one to give a secure
grip on the key. If the key thickness is too fine to guarantee a good grip in the clamps, a pin must be
used (fig. 15-A).
ATTENTION: the pins provided have two different diameters: 1,20 mm and 1,70 mm. It is essential to use pins
with the same diameters for locking both the original and the key blank.
Fig. 15
AB C
pin