Silca DUO POWER User manual

Operating manual
®
D434685XA
vers. 2.0
EN

© 2009 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: october 2010
Printed in India
by MINDA SILCA Engineering Ltd.
Plot no.37, Toy City, GREATER NOIDA
(U.P.) - 201308
IMPORTANT NOTE: in compliance with current regulations 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 TRANSPORT ...................................................................................................5
1.1 Packing ... ..............................................................................................5
1.2 Transport ... ...........................................................................................5
1.3 Unpacking .............................................................................................5
1.4 Handling the machine ...........................................................................5
2 DUO / DUO POWER machines WORKING PARTS ......................................6
3 DUO BRAZIL machine WORKING PARTS ...................................................7
4 MACHINE DESCRIPTION ...............................................................................8
4.1 Technical Data ......................................................................................9
4.2 Graphics . ..............................................................................................9
4.3 Electric circuit ......................................................................................10
5 ACCESSORIES PROVIDED .........................................................................11
6 MACHINE INSTALLATION and PREPARATION ........................................12
6.1 Checking for damage ..........................................................................12
6.2 Environmental conditions ....................................................................12
6.3 Positioning . .........................................................................................12
6.4 Description of work station ..................................................................13
6.5 Separate parts ....................................................................................13
6.6 Connection to the mains .....................................................................13
6.7 Cutter shield ........................................................................................14
7 MACHINE REGULATION AND UTILIZATION .............................................15
7.1 Checking and setting ..........................................................................15
7.2 Calibration - LEFT-HAND CARRIAGE ...............................................15
7.3 Calibration - RIGHT-HAND CARRIAGE .............................................17
8 CUTTING OPERATIONS ..............................................................................20
8.1 Key cutting ..........................................................................................20
8.1.1 Carriage release (right or left-hand side) ............................................. 20
8.1.2 Clamp rotation ..................................................................................... 20
8.1.3 Carriage translation on DUO key-cutting machine .............................. 21
8.1.4 Carriage translation on DUO BRAZIL key-cutting machine .................21
8.1.5 Flared cuts cutting bit keys (right-hand carriage) .................................22
8.2 Cutting flat cylinder and vehicle keys - LEFT-HAND carriage ............23
8.2.1 Using the accessories .......................................................................... 25
8.3 Cutting double bit, pump and mail box keys - RIGHT-H. carriage.......27
8.3.1 Cutting bit and double bit keys ............................................................. 29
8.3.2 Cutting keys with central stop .............................................................. 30
8.3.3 Cutting mail box keys ........................................................................... 30
8.3.4 Cutting pump keys ...............................................................................31
9 MAINTENANCE .............................................................................................33
9.1 Replacing the cutting tool ...................................................................33
9.2 Access to the lower part .....................................................................34
9.3 Replacing the brush ............................................................................35
9.4 Replacing and/or tightening the belt ...................................................35
9.5 Replacing the tracer point ...................................................................36
9.6 Regulating left carriage depth .............................................................37
9.7 Replacing the fuses ............................................................................37
9.8 Replacing main switch ........................................................................38
9.9 Replacing motor on switch ..................................................................39
9.10 Replacing motor/condenser ................................................................40
9.11 Replacing lamp ...................................................................................41
10 DISPOSAL ....................................................................................................42
11 ASSISTANCE ................................................................................................43
11.1 How to request service .......................................................................43

Operating manual - English DUO
Copyright Silca 2 010 3
GUIDE TO THE MANUAL
This manual has been produced to serve as a guide for users of the DUO 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 ....................................................................................... Ch. 1
- Description of machine and safety devices ........................................................ Ch. 2-3-4-5
- Proper use of machine ........................................................................................ Ch. 6-7-8
- Maintenance ........................................................................................................ Ch. 9
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
Fig. 2
1) Head
2) Rim
3) Stop
4) Blade
5) Tip
6) Back
7) Cuts
8) Stem
9) Bit
111
3
3
3
7
7
8
2
2
5
55
4
6
WITH LEFT-HAND CARRIAGE
only on DUO BRAZIL version
1
8
3
5
7
8
9
WITH RIGHT-HAND CARRIAGE
PUMP KEYS
ATTENTION: see chap. 8.3.4.
ONLY on DUO POWER version
ONLY on
DUO and DUO BRAZIL

DUO Operating manual - English
4 Copyright Silca 2 010
GENERAL INTRODUCTIONS
The DUO key-cutting machine has been designed according to the specifications of the Machine Direc-
tives. From the design stage risks for the operator have been eliminated in all areas: transport, key-cut-
ting, regulation and maintenance.
Other risks have been eliminated by the use of protective devices for the operator.
The protective devices us ed 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 the machine warning the operator to use goggles during the cut-
ting 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 DUO 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 DUO and benefit from its potential.
Instructions manual
The instructions manual provided with the machine is essential to i ts proper use and to carry out th e
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 DUO key-cutting machine is built entirely to standards. The operations for wh ich it has been de-
signed are easily carried out at no risk to the operator.
The adoption of general safety precautions (wearing protective goggles) and observation of the instruc-
tions provided by the manufacturer in this manual eliminate all human error, unless deliberate.
The DUO key-cutting machine 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 left-hand side of the machine;
- activating the motor on switch the left-hand side.
• 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 re-placed wrongly or unsafely.
• Machine Identification
The DUO key-cutting machine is provided with an identification label which shows the serial number (fig.
3).
Fig. 3
(*) see chap. 10 "DISPOSAL", page 42.

Operating manual - English DUO
Copyright Silca 2 010 5
1 TRANSPORT
The DUO key-cutting machine is easily transported and is not dangerous to handle. The packed ma-
chine can be carried by one person.
1.1 Packing
The DUO is packed in a strong cardboard box, the dimensions of which are shown in fig. 4, 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. 4
1.2 Transport
To avoid damaging the DUO 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) prise off the staples,
3) open the box without damaging it as it may be used again (e.g. removals, dispatch to the manufac-
turers for repairs or servicing),
4) check the contents of the box, which should comprise:
- 1 DUO key-cutting machine packed in a protective shell;
- 1 set of documents, including: operating manual, spare parts list and guarantee;
- 1 connecting wire;
- 1 tool kit
5) remove the key-cutting machine from the protective shell.
1.4 Handling the machine
When the DUO 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.
500
596
350
Keep dry This side up
Handle with care

DUO Operating manual - English
6 Copyright Silca 2 010
2 DUO / DUO POWER machines WORKING PARTS
Fig. 5
A - left-hand carriage
A1 - carriage lock/release pin - left-hand side
B - right-hand carriage
B1 - carriage lock/release pin - right-hand side
C - left-hand carriage movement lever
D - clamps for flat keys
D1 - gauges knob
E - clamps knobs (left-hand carriage)
F - prismatic cutter for flat keys
G - left tracer point for flat keys
G1 - centesimal ring - left tracer point
H - right-hand carriage movement lever
J - clamps for bit keys
K - clamps knobs (right-hand carriage)
L - tilting move ment activa ting pin (right-hand car-
riage)
M - milling cutter for bit keys
N - right tracer point for bit keys
N1 - centesimal ring - right tracer point
O - handwheel for carriage movement
P - brush
Q - top cover
R-lamps
S - chippings tray
T - main switch
U - motor on switch
V - supply socket
V1 - fuses
W - cutters protective shield
AB
C
D
E
H
A1
B1
JJ K
K
OL
N
G
G1
N1
F M
P
Q
R
S
WR
DUO / DUO POWER
TV U D1V1

Operating manual - English DUO
Copyright Silca 2 010 7
3 DUO BRAZIL machine WORKING PARTS
Fig. 6
A - left-hand carriage
B - right-hand carriage
C - left-hand carriage movement lever
D - clamps for flat keys
D1 - gauges knob
E - clamps knobs (left-hand carriage)
F - prismatic cutter for flat keys
G - left tracer point for flat keys
G1 - centesimal ring - left tracer point
H - right-hand carriage movement lever
J - clamps for bit keys
K - clamps knobs (right-hand carriage)
L - tilting movement activating pin (right-hand car-
riage)
M - milling cutter for bit keys
N - right tracer point for bit keys
N1 - centesimal ring - right tracer point
P - brush
Q - top cover
R-lamps
S - chippings tray
T - main switch
U - motor on switch
V - supply socket
V1 - fuses
W - cutters protective shield
A
B
C
D
E
H
JJ K
K
L
N
G
G1
N1
F M
P
Q
R
S
WR
DUO BRAZIL
TV U D1V1

DUO Operating manual - English
8 Copyright Silca 2 010
4 MACHINE DESCRIPTION
DUO is a professional key-cutting machine, designed to duplicate:
• flat keys for cylinders and vehicles and cruciform keys: with left-hand carriage.
• bit, double bit, pump and mail box keys*: with right-hand carriage.
Fig. 7
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 (T) powers the machine and illuminates the lamps (R) to indicate that current is on.
ATTENTION: Switch (T) 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
On the left-hand side of the DUO key-cutting machine there is also a switch for starting up the motor (U).
ATTENTION: the illuminated switch remains on to indicate that the key-cutting machine has been started
(cutter in motion).
Motor and transmission unit
Motor transmission takes place by belt.
On the right-hand side of the motor there is the transmission shaft which moves the brush (P).
On the left-hand side of the motor there is the shaft which moves the cutter spindle.
These components are protected by a top cover (Q).
Clamp carriages
The carriages comprise two clamps. They move horizontally and frontally controlled by handles (C and
H).
The DUO machine carriages can be locked into a fixed position and in this way achieve translation by
means of the flywheel located on the right-hand side of the machine (chap.8.1.3, page 21) (Attention:
not available on Duo Brazil version).
The carriages are so designed as to avoid accumulation of dust or cutting swarf.
The machine is designed with a ramp along which chippings can fall into the special chippings tray (S)
placed under the carriage and easily removable for emptying and cleaning.
Cutting unit
The cutting unit contains the actual wo rking parts of the DUO key-cutting machine , which operate to-
gether to cut and finish keys "read" from the originals.
The working parts are described below:
•Cutting Tools
The cutting tools (F) and (M) are the parts of the DUO used for cutting key blanks. The cutting tools are
in HSS super rapid steel and are protected by a special cover (W) to ensure safe operation. The shield
(W) is mobile and can be placed over the cutter that is not in use.
• Tracer points
The tracer points are dedicated to reading cuts on the key to be duplicated and are:
- tracer point (G) on the left-hand side of the machine, for flat keys for cylinders and vehicles and cru-
ciform keys;
- tracer point (N) on the right-hand side of the machine, for bit, double bit, pump and mail box keys*.
The depth of the tracer points is easily regulated by means of the relative graduated nut.
* Mail box keys only on DUO and DUO BRAZIL versions
DUO / DUO POWER DUO BRAZIL

Operating manual - English DUO
Copyright Silca 2 010 9
•Clamps
Left-hand carriage
The clamps (D) are rotating and four-sided to allow perfect closure of the key placed on its back or profile
in the case of keys with symmetrical cuts (chap.8.2, page 23).
Right-hand carriage
The clamps (J) are rotating, two/three sided to allow perfect closure of bit, double bit, pump and mail box
keys* (chap.8.3, page 27).
• Clamps knobs
The clamps are locked by two anatomical knobs (E) or (K), which ensure perfect grip on the keys with
only slight locking pressure.
•Calibration tabs
The clamps have two gauge tabs (left-hand carriage) with which to adjust key alignment.
•Brush
The brush (P) is used to eliminate burrs from the cuts and is made of non-abrasive material.
4.1 Technical Data
ELECTRICAL PROPERTIES:
- 230V-50Hz 300W 1,2A
- 120V-60Hz 250W 2,3A
CUTTING TOOLS: HSS Super Rapid Steel
MOTOR: One-speed single phase
- 230V-50Hz (1400 rpm)
- 120V-60Hz (1700 rpm)
MOVEMENTS: by gear on rectified carriage
CLAMPS: rotating 4 sides (left carriage), 2/3 sides (right carriage)
MAXIMUM LENGTH OF CUTS:
- flat cylinder keys: 42 mm
- bit and double bit keys: 25 mm
DIMENSIONS: width: 510 mm - depth: 450 mm - height: 280 mm
SONOROUS PRESSURE: Leq. = less than 70 dbA
WEIGHT: Kg.23
4.2 Graphics
* Mail box keys only on DUO and DUO BRAZIL versions
THE USE OF
PROTECTIVE GOGGLES
IS COMPULSORY

DUO Operating manual - English
10 Copyright Silca 2 010
4.3 Electric circuit
The main parts of the electric circuit on the DUO are listed below:
1) Main socket with fuses
2) Safety main switch
3) Illuminated switch
4) Motor: 230V- 50Hz (120V-60Hz)
5) Condenser
6) Lamps
2
3
4
1
blue blue
brown
brown
blue
brown
brown
blue
yellow/green
1
23
45
6

Operating manual - English DUO
Copyright Silca 2 010 11
5 ACCESSORIES PROVIDED
it is advisable to always have certain spare parts on hand. It is advisable to always have a tool box con-
taining: tools, cutting tools, brushes, belts and small replacement parts.
DUO is supplied with a full range of accessories. The accessories provided by Silca are all that is nec-
essary to carry out the operations for which the machine is designed.
STEEL PIN Ø 1,20
2 pcs
STEEL PIN Ø 1,70
2 pcs
FUSES 5X20 (2 pcs)
4 Amps rapid (230V)
8 Amps rapid (120V)
2,5 mm ALLEN KEY
3 mm ALLEN KEY
19 mm SPANNER
CUTTING TOOL
UNCLAMPING PIN
ADJUSTING BAR
2 pcs
4 mm ALLEN KEY
5 mm ALLEN KEY STEEL BAR
2 pcs
CLEANING BRUSH
ADJUSTING PINS
2 pcs

DUO Operating manual - English
12 Copyright Silca 2 010
6 MACHINE INSTALLATION AND PREPARATION
The DUO 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.
6.1 Checking for damage
The DUO key-cutting machine is solid and compact 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.
6.2 Environmental conditions
To ensure that the best use is made of the DUO 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 10 to 40°C
- relative humidity:
approx. 60%
6.3 Positioning
Place the key-cutting machine on a horizontal surface, solid enough to take the weight (23 Kg).
To facilitate operation and maintenance, install the machine with a space of at least 200 mm on all sides
(fig. 8).
Ensure that the machine stands perfectly balanced on the four feet. Vibration is avoided when the ma-
chine 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. 8
200 mm
200 mm
200 mm

Operating manual - English DUO
Copyright Silca 2 010 13
6.4 Description of work station
The key-cutting machine needs only one operator, who has the following controls at his/her disposal:
- Main switch (T), located on the left-hand side of the machine, it activates the machine and turn on
the lamps (R).
- Motor on switch (U), located on the left-hand side of the machine has a warning light to show that
the key-cutting machine is live.
Left-hand carriage:
- Carriage lever (C)
- Carriage release pin (A1) (not available on Duo Brazil version)
- Gauges knob (D1)
- Carriage advancement flywheel (O) (with carriage locked - chap. 8.1.3, page 21) (not available on
Duo Brazil version).
Right-hand carriage:
- Carriage lever (H)
- Carriage release pin (B1) (not available on Duo Brazil version)
- Carriage advancement flywheel (O) (with carriage locked - chap. 8.1.3, page 21) (not available on
Duo Brazil version).
- Tilting movement activating pin (L)
Fig. 9
(*) not available on Duo Brazil version
6.5 Separate parts
The separately packed parts must be installed on the DUO key-cutting machine by the p urchaser, as
follows:
Connection wire
Connect the key-cutting machine power cable
to the electricity mains (fig. 10).
Fig. 10
6.6 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.
T U H
CA1 B1 O
D1
L
***
RR
power
cable
electricity
supply

DUO Operating manual - English
14 Copyright Silca 2 010
6.7 Cutter shield
The shield (W) is mobile and can be placed over the cutter when not in use:
- to operate the left-hand carriage, take shield (W) to the right (fig. 11)
- to operate the right-hand carriage, take shield (W) to the left (fig. 12)
Fig. 11
Fig. 12
W
W

Operating manual - English DUO
Copyright Silca 2 010 15
7 MACHINE REGULATION AND UTILIZATION
7.1 Checking and setting
The cutting tools on the DUO are the parts used to cut the key blanks and should be periodically checked
and replaced, if necessary.
Every time the cutting tool is changed, and during periodical operational tests, check calibration.
7.2 Calibration - LEFT-HAND CARRIAGE
The DUO 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. 13).
The axis setting is fixed and is established on assembly in our workshops.
Fig. 13 Depth calibration:
Depth calibration is regulation of the cutting depth (fig. 13-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. 13-B).
3) Check that the adjusting keys adhere properly to the clamps.
4) Turn the gauge rod (D2) towards the operator so that the gauges come into contact with the adjusting
keys (fig. 14). Lower the gauge rod.
Fig. 14
5) Release the carriage by raising the release lever.
6) Raise the carriage and take up to the cutting tool (fig. 15).
7) Turn the cutting tool anticlockwise manually and check that it skims the adjusting keys in several plac-
es.
8) If necessary, regulate the depth of the cut with the micrometric tracer point, as follows:
a) loosen the screw (G2) holding the tracer point.
b) turn the ring nut (G1) clockwise to advance the tracer point (fig. 15 and fig. 16).
c) turn the ring nut (G1) anticlockwise to return (fig. 17).
B
64890
cutting
I II III IV V VI
cutting
space
depth
A

DUO Operating manual - English
16 Copyright Silca 2 010
ATTENTION: each notch on the centesimal ring corresponds to 0,025 mm (fig. 15-A).
9) Repeat these operations until regulation is complete, then tighten the tracer point locking grub screw
(G2).
Fig. 15
Fig. 16
Turn the nut to the RIGHT (clockwise) to take the tracer point down. Result: LESS DEEP CUTS
Fig. 17
Turn the nut to the LEFT (anticlockwise) to take the tracer point up. Result: DEEPER CUTS
0,025 mm
0,1 mm
A
G1
B
G2
cutting tool
G1
G2
cutting tool
G1
G2

Operating manual - English DUO
Copyright Silca 2 010 17
7.3 Calibration - RIGHT-HAND CARRIAGE
Axis calibration
Axial gauging is regulation of the spaces for the cuts on the key (fig. 18).
Fig. 18 Axis gauging control
1) Turn off the machine and unplug the power lead.
2) Make sure the tracer point and cutter are of the same thickness.
3) Lock the tilting movement of the clamps by inserting the pin (L) into its seat.
4) Close the 2 clamps with their knobs (K).
5) Release the carriage by turning the pin (B1) (not available on Duo Brazil version).
6) Use the lever (H) to raise the carriage and take the right-hand side of the clamp up against the left-
hand side of the tracer point and cutter (fig. 19).
7) The ideal condition is for both tools (tracer point and cutter) to be in contact with the relative side of
the clamp. If this is not so, loosen the 2 tracer point holder screws (N2) (fig. 19) and move the tracer
point holder manually (right or left) until the ideal condition is found.
8) Tighten the 2 screws (N2).
Fig. 19
cutting space
cutting
depth
LH
K
K
N3
B1
N2

DUO Operating manual - English
18 Copyright Silca 2 010
Depth calibration
Depth calibration is regulation of the cutting depth (fig. 18).
Proceed as follows:
1) Ensure that the key-cutting machine is off by unplugging the power cable.
2a) DUO and DUO BRAZIL: place the adjusting keys on the clamps (fig. 20-a) on the 2nd side for
mail box keys - fig. 38);
2b) DUO POWER: place the adjusting pins on the clamps (fig. 20-b) on the 1st side for bit/double
bit keys - fig. 39).
3) Lock the clamps in the horizontal position by means of the pin (L);
4) Raise the carriage and take the adjusting keys (or pins) into contact with the tracer point and cutting
tool (fig. 20).
5) Turn the cutting tool manually in the opposite sense to the rotation and check that it skims the adjust-
ing key (or pin) in several places.
6) If necessary, regulate the cutting depth by means of the tracer point, as described; loosen grub screw
(N3) and:
- turn the ring nut (N1) clockwise to advance the tracer point (fig. 21).
- turn the ring nut (N1) anticlockwise to return (fig. 22).
7) Repeat these operations until the cutting tool skims the adjusting key (or pin) in several points.
Fig. 20
cutting tool
N1
N3
N1
N3
a) DUO / DUO BRAZIL
b) DUO POWER