sks CYCLONE User manual

1
CYCLONE/CYCLONE PLUS
MANUAL

2
CONTENTS
PARTS DIAGRAM
3
MACHINE INSTALLATION & PREPARATION
4
Checking For Damage
4
Installation
4
Environmental Conditions
4
OPERATION & MAINTENANCE
5-8
Cutting a Key - Cylinder
5
Cutting a Key - Mortice
5
Replacing The Cutters
6
Machine Adjustment
6-7
General Maintenance
7-8
HEALTH & SAFETY
8

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PARTS DIAGRAM
1. Light bulb and cover
2. Voltmeter
3. Cutter guard
4. Cylinder follower
5. Cylinder cutter
6. Cylinder jaws/carriage
7. Swarf tray
8. Protective shield
9. Brush
10. Switch
11. Main switch
12. Mortice cutter
13. Mortice follower
14. Wheel handle
15. Mortice jaws/carriage

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MACHINE INSTALLATION & PREPARATION
The 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.
CHECKING FOR DAMAGE
The 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.
INSTALLATION
•Remove the machine from the box and place it in its working position on a flat bench or
counter
•Ensure that there is adequate lighting in the area and there is adequate space surrounding
the machine
•Fit the front handles to the key carriage and secure hand tight
•Fit the eye shield
•Fit the bulb cover and bulb
•Remove the red protective caps on the followers (4 & 13) before use
•Connect the machine to the mains power supply
•Switch the main power switch (11) on
•Check motor operation by switching the round switch (10) on
Please note, although the machine is calibrated at the factory, it is possible that the machine settings
are disturbed during transit. Please see ‘Machine Adjustment’ on pages 6-7 for instructions on how
to check and calibrate the machine.
ENVIRONMENTAL CONDITIONS
•Use in dry, well ventilated areas
•Ideal operating temperature 10°C - 40°C

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OPERATION & MAINTENANCE
CUTTING A KEY –CYLINDER
Please ensure the 4-way jaw is at the correct position and that the right and left hand jaws are both
set to the same side.
SIDE A: Standard cylinder keys positioned on their backs and cruciform keys
SIDE B: Small cylinder keys (depth of less than 3.9mm) positioned on their backs
SIDE C & D: Double sided cylinder keys and keys to be clamped on their groove.
To change the jaw position, loosen the knob then lift the jaw from the bottom and turn to the
correct position.
•Clamp the original key in the left hand jaw then raise the key set guide to sit against the
shoulder
•Position the blank key in the right hand jaw so that the shoulder sits flush with the other side
of the key set guide and tighten the clamp
•Lower the key set guide and power on the machine
•Raise the carriage to the cutter, apply a reasonable amount of pressure and use the wheel
handle to trace the original key from the shoulder to the tip
•Lower the carriage, turn off the power
•Release the cut key and deburr, if necessary, using the brush
CUTTING A KEY –MORTICE
•Place the original key in the right hand jaw, pushing it in from the right until it stops at the
shoulder
•Repeat for the blank key on the left hand jaw
•Power on the machine
•Follow the cuts on the original key by moving the carriage side to side with the wheel handle
and using the black carriage handle to raise the key to the cutter
NOTE –Do not move the carriage sideways whilst cutting into the key
•Once completed turn off the power, remove the key and remove any excess material with a
file or the brush
The Cyclone Plus has tilting mortice jaws to allow you to round the cuts. To use this feature you just
need to remove the pin from the carriage. To lock the jaws back into the fixed horizontal position
just reinsert the pin.

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REPLACING THE CUTTERS
WARNING! ENSURE MACHINE IS UNPLUGGED BEFORE UNDERTAKING ANY MAINTENANCE
•Remove the three screws holding the case on the machine (one each side and one at back)
then carefully lift the case off the machine
•Locate the cut-out on the shaft that runs between the two cutters and insert a 4mm allen
key (or similar) to lock the cutter shaft in position
•Undo the nut holding the cutter on (turning in anti-clockwise direction) and remove cutter
and washer
•Replace with new cutter, reusing the existing washer and tighten nut back on in clockwise
direction
MACHINE ADJUSTMENT
WARNING! ENSURE MACHINE IS UNPLUGGED BEFORE UNDERTAKING ANY MAINTENANCE
The machine calibration should be checked on a regular basis and especially after replacing the
cutter. There are two types of calibration, axis calibration which is regulation of the position of the
key left to right and depth calibration which obviously regulates the depth of the cuts
CYLINDER CALIBRATION
Axis Calibration:
Insert identical key blanks with shoulders on front and back into both jaws, lining them up with the
back shoulder against the jaw on Side A.
When correctly calibrated the key set guide should touch both shoulders and the tracer and cutter
should hit the shoulders simultaneously.
If the key set guide is out of alignment:
•Loosen the allen screws on the triangular guides
•Adjust until they are both touching the key shoulders
•Re-tighten the allen screws
If the cutter and tracer are out of alignment:
•Loosen the two large allen screws on the tracer housing
•Adjust the position of the tracer left or right until the tracer and cutter are both touching the
key shoulders
•Re-tighten the screws
Depth Calibration:
Insert identical key blanks with shoulders on front and back into both jaws, lining them up with the
back shoulder against the jaw on Side A.
When correctly calibrated, the cutter should skim the surface of the key on the right whilst the
tracer is making contact with the key on the left.

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If this is out of alignment:
•Loosen the screw holding the tracer point
•Turn the tracer adjustment ring (clockwise to extend tracer and anti-clockwise to retract it)
until the cutter skims against the blank on the right whilst the key on the left is against the
tracer
•Re-tighten the allen screw.
MORTICE CALIBRATION
Axis Calibration:
Insert identical key blanks with shoulders on front and back into both jaws, lining them up with the
back shoulder against the jaw.
When correctly calibrated the side of the tracer and the side of the cutter should hit the shoulders
simultaneously.
If this is out of alignment:
•Loosen the allen screw on the tracer housing
•Adjust the position of the tracer left or right until the tracer and cutter are both touching the
key shoulders
•Re-tighten the screws
Depth Calibration:
Insert identical key blanks with shoulders on front and back into both jaws, lining them up with the
back shoulder against the jaw.
When correctly calibrated the cutter should skim the surface of the key on the left whilst the tracer
is making contact with the key on the right.
If this is out of alignment:
•Loosen the top allen screw on the tracer housing
•Turn the screw under the tracer (clockwise to extend tracer and anti-clockwise to retract it)
until the cutter skims against the blank on the left whilst the key on the right is against the
tracer
•Re-tighten the allen screw
GENERAL MAINTENANCE
WARNING! ENSURE MACHINE IS UNPLUGGED BEFORE UNDERTAKING ANY MAINTENANCE
It is advisable to periodically check the parts subject to wear on the machine, e.g. drive belt, cutters,
brush, tracer points, etc.
For long lasting, satisfactory operation of the key machine the following regular checks are also
recommended.

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•Keep the machine clean of swarf, particularly the jaws and other moving parts using a dry
brush
NOTE –Do not use compressed air
•Ensure the sliding shaft is kept lubricated
•Check all screws and bolts for any slackness and tighten if necessary
HEALTH & SAFETY
For complete safety whilst operating the machine, please take the following precautions:
•Always wear safety goggles
•Always work with dry hands
•Check that the machine is properly earthed
•Keep loose clothing, ties, hair, etc. away from moving parts
•Only clamp keys when the motor is switched off
•Keep hands away from the cutters when the machine is in use
•Turn power off when not in use and ensure the machine is unplugged before undertaking
any maintenance