Silca Ilco Orion SMARTY 2000 User manual

®
D430568XA
vers. 3.0
Operating manual
SMARTY 2000

© 2002 SILCA S.p.A - Vittorio Veneto
This manual has been drawn up by ILCO ORION.
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 ILCO ORION.
Edition: june 2006
Printed in Vittorio Veneto
by ILCO ORION.
via Podgora, 20 (Z.I.)
31029 VITTORIO VENETO (TV) - Italy

INDEX
GUIDE TO THE MANUAL ......................................................................................................5
GENERAL INTRODUCTION.................................................................................................. S
1 TRANSPORT 7
1.1 Packing ..........................................................................................................7
1.2 Transport .......................................................................................................7
1.3 Unpacking ......................................................................................................7
1.4 Handling the machine ....................................................................................7
2 MAIN WORKING PARTS ................................................................................8
3 MACHINE DESCRIPTION ...............................................................................9
3.1 Technical Data .............................................................................................10
3.2 Electrical system ..........................................................................................11
4 ACCESSORIES PROVIDED .........................................................................12
5 MACHINE INSTALLATION AND PREPARATION .......................................13
5.1 Checking for damage ...................................................................................13
5.2 Environmental conditions .............................................................................13
5.3 Positioning ...................................................................................................13
5.4 Description of work station ...........................................................................13
5.5 Graphics ......................................................................................................14
5.6 Separate parts .............................................................................................14
5.7 Removing the blocks ...................................................................................14
5.8 Connection to the mains ..............................................................................14
6 REGULATION AND USE OF THE MACHINE ..............................................15
6.1 Checking and setting ...................................................................................15
6.2 Calibration ....................................................................................................15
7 Key cutting ....................................................................................................16
7.1 Key cutting ...................................................................................................16
7.2 Using the accessories ..................................................................................17
8 MAINTENANCE .............................................................................................19
8.1 Replacing the cutting tool ............................................................................19
8.2 Replacing the brush .....................................................................................19
8.3 Replacing the belt ........................................................................................20
8.4 Replacing the tracer point ............................................................................20
8.5 Replacing the fuses .....................................................................................20
9 DISPOSING OF MACHINE ...........................................................................21
10 AFTER-SALES SERVICE .............................................................................22
10.1 How to request service ................................................................................22

Operating manual - English SMARTY 2000
5
GUIDE TO THE MANUAL
This manual has been produced to serve as a guide for users of the SMARTY 2000 key-cutting
machine. 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
- Description of machine and safety devices
- Proper use of machine
- Maintenance
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
2
1
5
7
3
6
4

SMARTY 2000 Operating manual - English
6
GENERAL INTRODUCTIONS
The SMARTY 2000 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.
A special adhesive label is attached to the 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 SMARTY 2000 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 ILCO ORION 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 SMARTY 2000 and benefit from its potential.
Further Risks
There are no further risks arising from the use of the machine.
Protection and safety precautions for the operator
The SMARTY 2000 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 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.
The SMARTY 2000 key-cutting machine is designed with features which make it completely safe in all
its parts.
• Power supply
The key-cutting machine must be supplied with electricity by means of a safety device (standard with
230V key-cutting machines, on request for other voltages). The plug must be earthed.
• Start-up
The machine is started up by means of:
1) the main switch on the safety device (supplied with the 230V machines);
2) the ON switch, situated on the machine, which activates the machine motor.
• 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 SMARTY 2000 key-cutting machine is provided with an identification label which shows the serial
number (fig.2).
Fig. 2
(*) see chap. 9 DISPOSING OF MACHINE, page 21.

Operating manual - English SMARTY 2000
7
1 TRANSPORT
The SMARTY 2000 key-cutting machine is easily transported and is not dangerous to handle. The
packed machine can be carried by one person.
1.1 Packing
The SMARTY 2000 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 the SMARTY 2000 it must always be transported in its packing 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) open the box without damaging it as it may be used again (e.g. removals, dispatch to the
manufacturers for repairs or servicing).
3) check the contents of the box, which should comprise:
- 1 SMARTY 2000 key-cutting machine packed in a protective shell;
- 1 set of documents, including: operating manual, spare parts list and guarantee;
- 1 carriage lever handle;
- tools;
- 1 safety device ( supplied with the 230V machines );
4) remove the key-cutting machine from the protective shell.
1.4 Handling the machine
When the SMARTY 2000 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
.
430 mm
500 mm
330 mm
Keep dry This side upHandle with care

SMARTY 2000 Operating manual - English
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2 MAIN WORKING PARTS
Fig. 4
A - carriage movement lever
B - gauge knobs
C - tracer point
C1- tracer point locking grub screw
D-motor
D1- motor start switch
E-brush
E1- brush cover
E2- cover fixing Allen screw
F - cutting tool
F1- cutting tool cover
G - clamp carriage
G1- carriage handle lever
H - clamps
H1- clamp knobs
X - safety device ( supplied with the 230V machines )
X1- main switch
X2- warning light
X3- plug
E1
E2
H G G1 F1 F
E
H1
A B C C1 D1 D
X1
X
X2 X3

Operating manual - English SMARTY 2000
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3 MACHINE DESCRIPTION
SMARTY 2000 is a professional cutting machinefor flat keys used with cylinder, car locks and cruciform
keys. The main parts of the machine are described below:
Safety device
The device is connected to a power plug with a differential switch, power the key-cutting machine by
pressing the switch (X1).
The warning light (X2) illuminates to indicate voltage in the plug (X3).
ATTENTION: switch (X1) 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 by means of theplug
(X3).
Motor start-up switch
The motor start-up switch (D1) is placed on the left-hand side of the SMARTY 2000 key-cutting
machine.
ATTENTION: the illuminated switch is always lit to show that the key-cutting machine is live.
Motor and transmission unit
The motor has belt transmission. The transmission unit is placed on the left of the motor and activates
the brush (E) and cutting tool (F). These components are protected by three covers:
- brush cover (E1),
- cutting tool cover (F1).
Clamp carriage
The clamp carriage (G) consisting of two clamps (H), is fitted to the horizontal movement carriage,
controlled by lever (A) and is provided with a handle (G1).
Cutting unit
The cutting unit contains the actual working parts of the SMARTY 2000 key-cutting machine, which
operate together to cut and finish keys "read" from the originals.
The working parts are described below:
•Brush
The brush (E) is used to eliminate burrs from the cuts and is made of non-abrasive material.
• Cutting Tool
The cutting tool (F) is the part of the SMARTY 2000 used for cutting key blanks. The cutting tool is in
TiAl super rapid steel and is protected by a special cover (F1) to ensure safe operation.
• Tracer point
The tracer point (C), used for reading the profile of the key to be copied, is housed on the right-hand
side of the machine base. Assures regulation of the depth.
•Clamps
The clamps (H) have two sides (fig. 9 - pag. 14), which rotate to allow the key to be perfectly secured
on its back or in profile.
•Clampknobs
The clamps are locked by two anatomical knobs (H1) which ensure perfect grip on the keys with only
slight locking pressure.
• Calibration tabs
The clamps have two gauge tabs, with which to adjust key alignment.

SMARTY 2000 Operating manual - English
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3.1 Technical Data
ELECTRICAL PROPERTIES:
- 230V-50Hz 190W- 1,5A
- 110V-60Hz 250W -3,5A
CUTTING TOOL: HSS (Super Rapid Steel)
MOTOR: One-speed single phase
MOVEMENTS: by ball joint on rectified carriage.
CLAMP: rotating with two sides, high precision.
MAXIMUM LENGTH OF CUTS: 45 mm
DIMENSIONS: width: 360 mm; depth: 450 mm; height: 290 mm
CUTTING NOISE:
- Lp(A) = max. 92,9 dB(A) (steel)
- Lp(A) = max. 85 dB(A) (brass)
WEIGHT: Kg. 23